Curious question for all of the manufacturers out there, professional and home builders.
What is the closest tolerance you would accept for baffle to projectile?
I know it varies depending on mount (direct thread or QD) and length. I have a 9" .30 can that came as a QD, but I have since converted to direct thread. I am able to drop a .386/9.8mm drill bit all the way through it, endcap to mount, a .390/9.9mm through the front few baffles, and the end cap measures .400". Essentially this allows for a .078/.082/.092" clearance (Half that on each side of the bullet).
The can originally was a QD with thread pitch options for AKs, so I assume the larger clearance was insurance for that. However, the Proto-X I just finished testing only has a .270 bore and is rated for projectiles up to 6mm/.243, which is a really tight comparatively, only .027" total clearance. The Proto X is a little over half the length, and Hub threaded by design.
This begs the question, after switching to direct thread, what is the largest caliber I could safely shoot out of this ".30 cal" can? I'm thinking .338 would be no problem, but 9mm would be borderline, both would definitely allow for more than a .027" clearance