Djandj,
I know I can't give you any new advice. In one respect or another your problem is "head-spacing". You comment above indicates you don't understand the problem. Both TactAdv and I told you Troy wasn't going to solve your problem since you only sent him the barrel and consequently he couldn't check for a headspace problem.
IMO it's one of three problems:
1 - Head-spacing is too loose. It may work for .303 but I doubt the 7.62x54R is as tolerant as the Britishround. The 7.62 only has to move a very small amount for the pressure to see the thin wall od the case.
2- Timing is off so that the bolt is opening too early allowing too much pressure on the case as it extracts.
3-The bolt is hitting the two lugs on the receiver before it closes on the cartridge. Could happen but not as likely as the two above.
Here is some relevant reading material:
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Headspace 101 for .303s in The Lee Enfield Forum Forum
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The Bren can be checked for headspace with practically no tools or gages. More to follow.
JoeInformation
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