Did my final testing today and I'm going to call the project complete.
Here are a couple of things that I've noted during the entire process that I learned that may help someone else.
A single .095" diameter barrel port placed midway between the gas block and the muzzle on my 8.5 inch barrel dropped my velocity 30 feet per second.
The sound duration of the fired shot with the old suppressor lasted .69 seconds before. After the new suppressor was added, the sound duration dropped to .47 of a second in duration. That's a pretty significant drop.
Overall, it is more quiet because the design is more effective, and as I noted above, the duration of the sound of the shot is also shorter, which helps make it "sound" more quiet too because the sound doesn't last as long as it did before.
I had some different loads with different powder and bullets worked up to test today, but only remembered to bring the ones in the magazine with me, but all of them should be within reason to point of aim. Not exactly of course, but close enough for minute of whitetail vitals at the distance that I hunt.
The test group today was shot with 190 gr noslers. The same bullets as I have been doing the sound and function testing with.
The other bullets I was going to shoot today were 220 gr sierra matchkings, 223 gr cast leatherheads, and some 240 gr sierra matchkings but like I said, I forgot them on my bench and it'll be another day before I test them.
I didn't readjust the scope from when I disassembled the gun to put all of this back together. It had been zero'd from last year when I built the upper and I simply can't remember which bullet weight and powder combo that I had used to zero it in the first place.
So, after shooting a 5 round group and seeing that it's about where it should be, this project is done.
By all means, I don't think there was a point of zero shift from the new suppressor, or from taking it apart and putting humpty dumpty back together again. The bullseye is about as round as a pop can.