The gunsmith's stoning of the internals seems to have worked.  Between us we have put 46 rounds of Hardcast 220 and 200grain Underwood and Double Tap ammo through the gun without a malfunction.  I have more ammo coming in Tuesday to continue to test.  I think I'll probably end up running Underwood 200gr Hardcast.  It shot perfect horizontally and about 2.5" high with the way the new tritium/fiber optic sights are set.   My practice ammo (Fiocchi 180gr JHP) shoots the same, so it's a good combo for me.  The same can be said both of these ammo choices in my 1911 10mm.  The Double Tap 200gr shot a couple inches to the right the way the sights are set.

I tried a 22 and 24lb recoil spring, tried +10% Wolf mag springs, tried putting 2 factory mag springs in one mag.  I tried every possible combo of those things.  Nothing worked for me, hopefully it was just a burr somewhere in the gun that is now fixed. 

My gunsmith is bringing it back this weekend.  He moved to Texas this year and hasn't been back home since I sent the gun with him.

He says it fed fine with limited amount of hardcast he took with him after some work.  It was a mix of Buffalo Bore and Underwood.  He didn't find any more locally to try.

He first polished the feed ramp and that did not work.  Then he polished the trigger bar and other internals.  He said it works now, also the trigger pull dropped from 8.5lbs to 5.5lbs.  I have 90 rounds of hardcast in 200-230gr weights from Underwood and Double Tap waiting for it to arrive.  I will post again once I get it shot and hopefully find a load that will work for me.

Thanks everyone for the input. 

I guess if it shoots fine for him I'll know what the problem is.  Thanks everyone.

My G20 is off at the gunsmith's now with some of the HC ammo.  I'll see what he figures out.  The other 10mm I traded for, a Sig Tacops 1911 is feeding everything fine so far.  Maybe it was just me.  The HC ammo in the G20 didn't seem to kick noticeably more than the 180gr at 1250fps JHP ammo I shot through it, and I never had a failure to feed in around 400 rounds of that through the G20.  Would bad shooting form cause jams with one and not the other?

Thanks and sounds good.  I won't be in AK again until Sept 2020, this year I hope to be in Colorado chasing mule deer.  Just black bear there.  I'll pack a handgun on our scouting trip but just the rifle on the hunt itself.  Less danger and more walking in Colorado.

Another 120 rounds through the Sig Tacops without an issue of any kind.  I am getting even better with it as I get more used to the trigger.  Man I love the flat trajectory of the 10mm at longer ranges compared to my old 230gr 45's in my other 1911!  It's in the running for my favorite handgun now, it might have my 386XL Hunter beat before long.

It's 10oz heavier than the Glock G20 with both fully loaded.  That's significant but not a complete deal breaker to pack hunting.  If I ended up having a rifle or scope failure on a remote drop camp hunt (unlikely with my rifle but not impossible) I would feel more comfortable taking an animal with the 1911 and it's trigger.  I can't take a back-up rifle on a hunt like that due to weight limits on the bush or float plane.  Worst case a handgun I'm comfortable with to 50 or 60 yards might save the hunt.  It's a very unlikely scenario but with multiple river crossings, terrible weather, rough terrain, and climbing something bad could happen to a rifle.

I ended up getting a Sig Tacops 1911 in 10mm.  I traded my commander size 1911 Sig Scorpion in on it.  I like the full size versions better for my use, I kept my Ruger Night Watchman SR1911.  My primary carry gun is a Sig 938, I really like the 1911's. 

The gun shop helped make my decision.  The only SAO P220 they could get is the Kryptek hunting version.  It is more expensive and doesn't have the night sights I wanted.  They could get the Tacops 1911 so I could trade my 45 in on it. 

I shot a few mags through it today after tearing it down and cleaning it.  I had no failures of any kind I shot it well.  I shot my rolling ball target that's about 6" in diameter with the 180gr Fiocchi JHP ammo.  I had no trouble rolling it most every shot between 15 and 50 yards.  Sights must be pretty well on for that ammo at least.  I need to get a holster coming for it now since my other 1911 holsters won't fit the rail on this one.  I haven't tried my bear loads through it yet.

Recoil seemed sharper than my G20 despite the extra weight.  Probably due to the metal instead of polymer frame.  It wasn't uncomfortable or hard to control, just felt it a little more.

I really like the new gun.  I now have a really nice line-up of guns I can carry while scouting, hunting, or fishing.  S&W 60, 386 XL Hunter, and 69 in 357 and 44 magnum, plus the G20 and 1911 Tacops in 10mm.  Also an old Ruger P97 in 45 that likely won't see much woods use now that I have the 10mm's.

I really like the new 10mm.  All the features I want (night sights, rail) with a trigger I'm already darn good at running unlike the G20.

Good info thanks guys.

I've tried the double mag spring without success.  I have not talked to Glock but did talk to Underwood and KKM.  KKM recommended trying Double Tap ammo, they said that is what they test with.  I have some on order so I'll try it as soon as it shows up.  The only thing I've had success with so far is the UW Extreme Penetrator 140 grain.  Underwood considers that a bear worthy load.  KKM also said they would polish the feed ramp more if the DT ammo doesn't work.  I still have my doubts that the feed ramp is the problem since it occurs with either the factory barrel or the KKM barrel and both the factory and 22lb recoil springs.

After talking to KKM they recommend trying Double Tap ammo.  I have some on order.  I have my doubts that it will work though, the HC failures occur with the factory barrel also and either the 22lb or factory recoil spring.

Underwood Extreme Penetrators have fed flawlessly (40 rounds) and Fiocchi 180gr JHP's (300+ rounds) have fed without a single malfunction.  That is with any combo of barrel, recoil spring, and mag spring I have tried.  Not sure what the deal is. 

Thanks everyone for the replies.

I got a couple Razco holsters for my G20, and probably will for the second 10mm I choose also.  One attaches to the bottom of my FHF bino harness and uses the same straps.  It makes it one less thing to take loose when layering up and down for changing weather and activity levels when hunting or scouting.  The second is a plain Razco chest holster that doesn't attach to the bino harness.  Both are made to fit the G20 with the Streamlight TLR-1 light attached to the rail and work great.  Very good fit, design, and quality.

Whatever gun ends up going to Alaska with me I will also have him make a kydex paddle holster for to fit the gun and the light.  Several of the hunting pants and rain pants I use have a built in belt to keep a low profile under the hip belt of a pack.  There isn't a good place to put a holster on one.  For use around camp I'd like to have a paddle holster I could slide into the pants quick without needing to get the chest holster out.  It would make me less likely to not have the gun when needed if it was convenient to slide it in to go after firewood, go to the latrine area, walk to the river, etc.   

After doing some more looking I'm pretty well set on a Sig.  I'm still waiting on my local gun store to get back with me on pricing of both the 220 Elite SAO and the 1911 Tacops 5".  They both have the rail and night sights I want, and I've always had good luck with Sig.  I haven't ever owned a Colt.  Lots of companies make a darn good 1911 but the Sig fits my needs at a price I can handle.  It comes with 4 mags if I go that route which is a plus.

Anyone know of any issues with the Sig 1911 and heavy hardcast loads?

I have a Ruger SR1911 Night Watchman in 45 and really like that gun.  I had a Commander size SR1911 stolen a while back.  I like the Rugers, but they don't offer the rail I want on this gun.  I definitely want a light rail on whatever I go with.

I should add, I tried the factory barrel, recoil spring, mag, stock everything with the 220gr Underwood HC earlier today also, 2 failures to feed in 5 rounds. 

Thanks very much, that is sure worth a shot.  I'll give it a shot when my 22lb spring arrives if that doesn't fix the problem.  I'll try the double mag spring with the stock and 22lb springs first since I already have them.  I'm not worried about capacity, the chance of getting more than 2-3 rounds off if I have to deal with a bear is pretty small.  I just want reliability and accuracy for those rounds.