Sounds like your bolt catches are made very poorly. I like a lot of Aero's stuff, but after 2 have broken, I wouldn't be putting any more in.
I've never had a bolt catch break using the appropriate rifle buffer in a .308 A2 configuration.
Are you saying you put a carbine style buffer in your rifle with the A2 tube still?
Looks like this?
If so, that is a bad idea. The shorter buffer will allow the larger diameter of the body of the bolt carrier to impact the threaded portion of the lower receiver, which can cause damage to the threads, and eventually can cause the lower receiver to crack at the base of the buffer tube hole.
I bought a DPMS from a guy that had put a carbine buffer in an A2 rifle buffer tube, and the carrier had dug into the buffer tube threads about a 1/4 of an inch.
It's your gun, do as you wish, but understand that they are designed with that buffer for the rifle A2 tube for a reason.






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