I filled in the alignment channel on my flat-hopped barrel with RTV silicone, but only had a noticeable increase of about 2 or 3 FPS, compared to the barrel before the filling.
The only other thing I can think of that might be affecting the FPS, is what Steve suggested; the area of contact. I'm beginning to wonder if there might be some manufacturing tolerance variations in the diameter of the two barrels which would account for the difference? Either way, I'm happy with the result as the FPS appears to be a bit more consistent overall.
I also filled in the alignment channel on a 300mm madbull tightbore I have, and got a bump of about 10-15fps. I'm going to chrono it a few more times with different weight ammo, as I feel the results are too good to be true.
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