I thought I would add my experiences to this thread. Last month I bought a Mossberg 590 12-gauge (serial number starts with a P and I don't have it with me at the moment to get any of the numbers... I haven't contacted Mossberg for the year of manufacture, either) from a friend of a friend for home defense. It has the longer magazine (8+1 2 3/4 cartridges), a heat shield, and it's pre-tapped for sights or a rail. It had never been fired, and I got it for a great price. It's my first shotgun, so I didn't know anything about them so this has been a real learning experience.
After buying some Fiocchi #4 buckshot rounds and trying to run them through (without firing), I discovered that they would fall out the bottom of the receiver. The friend I went through to buy the gun gave me some bird shot rounds to run through and those would intermittently rack correctly, but some would end up falling out the bottom. We cleaned the magazine tube and the follower thinking that might have been the problem, but to no avail: rounds were still falling out the bottom.
I had to go on a trip for a week, so when I got home I went to my local outfitters and purchased some A-Zoom snap caps to run through (the thought of running live rounds through it was still somewhat frightening to me at this point) and they racked perfectly. Being unfamiliar with the mechanics of shotguns, I downloaded the manual (for the breakdown instructions and exploded diagram) and read up on how it worked. I also spent an hour or so comparing the difference between how the A-Zooms and the Fiocchi rounds went through the gun. As an aside, I learned a TON about how the gun functions and would recommend everyone spend at least 15 minutes watching how all of the parts move in their shotgun.
I had been browsing this site (particularly this thread and some of the other sites linked to in this thread) ever since I first had trouble with the gun, so I was aware of problems with the cartridge stop, however it was properly getting out of the way for both the A-Zooms and the live cartridges. (Note: directions like top and bottom in the next few sentences will be relative to the gun in a firing position rather than on a bench taking it apart) What I found was that when the forearm was pulled back, the cartridge interrupter (part #12 on the exploded view in the manual) would engage and pinch the live rounds against the top of the magazine tube, but it did this milliseconds after the cartridge stop was out of the way so the cartridge was slightly past the stop. Once the forearm was pushed forward, the interrupter would lower and release the cartridge into the receiver (since it was past the stop) and it would drop out the bottom. I figured out the cartridges were pinched because with the forearm pulled back, I was unable to move the cartridge in the magazine: it was stuck. With the cartridge stuck, I could take a small screwdriver, use the receiver as a fulcrum, and push the interrupter down to release the cartridge.
With this knowledge (and two great videos I found:
http://youtu.be/oahhxCMDFB8 and
http://youtu.be/GX8GsZNQpds), another friend and I slowly ground down the end of the interrupter to allow all cartridges to pass through. Note: we did this VERY slowly. I think I disassembled and reassembled the receiver 5-7 times, each time only taking off a very tiny bit of the interrupter with a Dremel. Our thought process was that if we took too little off, we could always take it apart and take more off; if we took too much, we couldn't put any back on
. It was a slow process, but it paid off!
I took it out to the range yesterday and put 24 rounds of birdshot and 8 Fiocchi rounds through it and had no misfeeds. I'm also happy to report that I have a nice bruise on my shoulder (remember, I'm a shotgun newb). Thanks to all the people who posted in this thread. It saved me from taking the gun to an expensive gunsmith, sending it to Mossberg, or returning it. Hopefully this post can help someone else in the future.