Originally Posted by Back40Bob
My biggest issue is, i can't separate the upper from the lower because the bolt will not seat to allow the hinge to work.
thanks in advance
Have you tried pulling BOTH take down pins (Rear AND Front)???
If that doesn't do it - robocop nailed it.....
Remove the handguards, tap the gas tube roll pin out of the front sight base (1/16"). Lock the bolt to the rear and CAREFULLY grab the gas tube with a small pair of vice grips behind the front sight base (DON'T CRUSH THE TUBE!) and work it back out toward the receiver. After it's free from the front sight base, then pull it out of the upper receiver.
If you are right about the gas key being damaged, the bolt should then fully close.