BCG getting stuck without buffer tube installed

[CartridgeCalls]

I have Geissele triggers in all my ARs.

I have several geissle as well. They are OK.

[AregularGuy]

Have you swapped that trigger out for another? I hate to think you'd have to file down a new, and expensive, part to get the rifle to work. That would be my last resort. If you swap out that trigger and still have the issue I'd say the lower is out of spec since all other parts seem to be functional in other configurations. Or swap trigger in known good rifle and see if trigger is out of spec.

[AregularGuy]

Does badger ordnance make lower receivers? Or is this the buffer tube you're taking about? Is the receiver milspec or some billet cut design? Maybe you can compare measurements to another milspec lower.

[SVT-40]

It's a timney drop in trigger which is definitely higher quality.

Not necessarily true. Try a standard non drop in trigger group. If that functions as it should , then the issue is your "higher quality" non standard drop in trigger.

I've had a drop in trigger cause issues such as you are having (hammer dragging on the bolt carrier). Personally I no longer use drop in triggers as they require retaining pins which are prone to breakage.

[CartridgeCalls]

Not necessarily true. Try a standard non drop in trigger group. If that functions as it should , then the issue is your "higher quality" non standard drop in trigger.

I've had a drop in trigger cause issues such as you are having (hammer dragging on the bolt carrier). Personally I no longer use drop in triggers as they require retaining pins which are prone to breakage.

With a geissle or a milspec standard it still has the same issues.

[SVT-40]

With a geissle or a milspec standard it still has the same issues.

Well that's disappointing.

Have you tried installing another complete upper on the problematic lower?

[ar15barrels]

With a geissle or a milspec standard it still has the same issues.

If swapping bolt carriers will not solve it, replace the bad lower or modify your hammer to add clearance.
these are your options.

[CartridgeCalls]

Well that's disappointing.

Have you tried installing another complete upper on the problematic lower?

Yes I have, same exact issues.

[SVT-40]

Yes I have, same exact issues.

Then it's the lower with a out of spec. hammer pin hole.