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Cardinal / Kotonics used a #44 drill diameter (.086") on their 16" 6.8 mid length gas tube barrels.

Kerry
 

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Just remember the old saying its not very hard to take metal out but you will have a hard time putting it back on.

Take the lightest load you plan on shooting. Put a standard carbine spring and carbine or H NOT H2 or any other size buffer in. you want to set the port so that ammo will eject reliably probably around 4:00.

Start small and you can always one it up more as I eluded to above. Start at aorund .078 and then work up on wire size at a time until you get proper function. Alsmot every factory barrel I have seen is over gassed. NOt only is this a pin as you have to use heavier buffers etc but it also shortens the useful life of the barrel as gas ports only get bigger with use and once they are too big you have to trash the barrel from the erosion. The other way is to take the hottest round you ever plan to load and have it eject at 2:30 3:00 with that same setup.
 
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