The whole thing made me reorganize my garage, much nicer now for reloading and wife should be happy as well. I think I figured out the gas block now, I guess research would have been in order earlier but glad I got it done now. I'm new to AR's so I thought the block was the one restricting the airflow, not the hole. Now that I have ideal flow for subsonics, I would have to get an adjustable block to restrict the airflow IF I wanted to shoot large amounts of supersonics. I think I'll manage for now since I built this just for subsonics.
For supersonics I have plans for bolt guns in 22-250, .308 and/or 6.5x55. Of course AR10 in .308 wouldn't be bad idea, unless you ask the wife... :)
Now I just have to set the drill press back into neck turning setup as the SI Defense uses 1.40" length with 0.01" neck diameter. By far the most time consuming task in forming brass from .223, that's why I had to use the drill press. Lathe might be a "must" purchase now so I can thread my own barrels too.