As long as the lower still has a pistol buffer and your state doesn't have weird pistol rules, I think you should be good.
@Club Sandwich should be the person to answer this question though
thanks for the notice.
In short, I wanted to know just how much extra noise, recoil, and blast there is out of an 11.5-12.5 inch barrel in 5.56 compared to a 16” rifle with a mid length gas system. Is it that much harder to manage? Is it going to limit reliability and durability?
"blast" is generally perceived gas volume outside the barrel when the bullet immediately passes the crown or muzzle device. ports in compensators and brakes redirect, slow, and cool blast in order to achieve various effects. recoil boosters and suppressors with blast chambers do this as well. the gas volume will depend very strongly on the precise chemistry of propellant you are using. a 5.56x45 NATO cartridge will be different between barrel lengths or gas port size (more on this later) because the powder charge, bullet mass, and so on is slightly different. this is because propellant used to force the bullet through the rifling will expand faster or slower, will be hotter or cooler, and this expansion difference is felt/experienced blast/noise/recoil. you've already probably assumed a shorter barrel will have more unburned powder compared to a longer barrel, and the lack of barrel length will allow most of this unburned powder to expand outside the barrel. this creates, generally, more noise, more blast, lower velocity (typically), and in some cases more perceived recoil from the lack of weapon mass that help mitigate recoil (heavy guns recoil less as it takes more energy to move greater mass).
the rule of thumb is about 100 fps loss per inch traveled, assuming all other factors are equal and the barrel is an ideal length and twist for the powder charge and bullet mass. because many 5.56 designs rely on high velocity fragmentation on penetration of a target (with secondary effects being tumbling inside the target), you must be aware of the velocity threshold your particular bullet requires for optimal performance. bullets that aren't meant for that purpose (or are for some other application) would not have this requirement in mind when choosing a barrel length.
as far as durability is concerned, shorter barrels have less mass to absorb heat and on long strings of fire can experience more deflection at longer ranges, which "opens" a given group up. at the same time, counter-intuitively, shorter barrels are "stiffer" and do not experience as much "barrel whip" from harmonics as the pressure wave passes through the barrel (like a sound wave). this stiffness can be a good thing if you're only taking a few shots here or there, or you use a bipod frequently. likewise the lighter weight might shift the balance of a rifle (or pistol as the case may be) into an awkward position. it is often true that shorter barrels have shorter useful life spans as well, because erosion from hot gases that are at higher than average pressure will "cut" into the gas port opening, slowly increasing it's size until the gas system fails to function reliably.
that being said, "blast" will generally not throw off a bullet (unless the muzzle or crown is damaged or something), and will instead generate additional flinch on the part of the shooter - the powder expansion and fireball some find to be uncomfortable or startling, likewise with the concussive pressure wave from very short barrels, and possibly a fireball from ignition of the powder outside the barrel - especially at night where you have darkness-adapted vision.
for "reliability", you must keep in mind that you're dealing with a pressurized system:
1. the trigger disengages from the hammer's sear and the hammer, driven by a spring, impacts the firing pin, which strikes the primer of the chambered cartridge. that primer ignites the powder in the cartridge case, which attempts to expand in all directions.
2. because the case is supported by the chamber, and the bolt is locking the rear of the cartridge in position, the only exit for pressure is forward, overcoming the crimp at the cannelure to push the bullet down the barrel, engaging the rifling to impart spin.
3. this pressurized system continues to expand from the propellant until the bullet passes the gas port in the front sight block. this allows some expanding gases from combustion to travel through the gas port and back through the gas tube to begin expanding in the bolt carrier, against the rear of the bolt. this begins unlocking the bolt from the barrel extension.
4. the time from when the bullet passes the gas port to the time the bullet exits the barrel entirely, is known as "dwell time", typically measured either in units of length or units of time. it is during this period that the gas system is pressurized enough to drive the action, and excess gas is vented out the end of the barrel - no longer contained by the bullet in flight.
5. a longer length of barrel between the gas port and the muzzle will increase dwell time, allowing the action to be gentler, and operate smoother.
6. too short of a dwell time can lead to under-pressure of the system, causing short strokes of the bolt carrier assembly, failure to unlock, extract, eject, cock, feed, or lock.
7. too long of a dwell time can lead to over-pressure of the system, causing premature movement of the bolt carrier assembly, failure to unlock, extract, eject, cock, feed, or lock.
in most short barreled AR-15 pattern rifles, the gas port is fairly close to the muzzle and the gas system requires balancing to ensure smooth operation. this is achieved in three primary ways:
1. adjust the gas port size to allow more or less gas into the gas tube. shorter barrels, being closer to the chamber, will often need a smaller than normal gas port to maintain a consistent volume of gas for the dwell time allowed by the position of the gas port in relation to the muzzle. because it is often unfeasible to adjust gas port size by the end user, this option is only relevant for gunsmiths or experienced users comfortable with the procedures to enact this change.
2. adjust the reciprocating mass of the bolt carrier assembly. a heavier mass requires both more time and more gas to move than normal. shorter barrels will often have a combination of a heavier recoil buffer (starting at H1 for carbines and moving to H2 and H3 for shorter barrels) and a heavier recoil spring (unless you have a very unusual configuration, the default Rifle or Carbine recoil springs will be appropriate). this option is both the easiest and most appropriate for the end user, but requires either experience or experimentation to tune a gas system and reciprocating mass to function reliably. short barrels will typically already have an appropriately sized gas port for most ammunition, and a recommended buffer to use with it.
3. lastly, certain combinations of carriers, muzzle devices, and gas tubes can be installed to meet specific requirements. this option is typically tailor-made for a specific weapons system.
i would suggest sticking with option 2.
this is a handy chart for determining a reasonably reliable SBR build for a given barrel length, gas port size/position, and bullet:
As a side note, let’s say I buy a pistol lower build kit alone then mate one of his short uppers to it temporarily. Am I good to then just get a mid length upper without reclassifying the firearm? Does that satisfy the mystical ATF voodoo bullshit? Money is tight and I want the option to switch uppers on the same platform without having to buy another complete lower.
in the US, for the AR-15, the lower receiver is considered the "firearm" in the legal definition of "firearm" and was transferred to you either as a pistol, rifle, "firearm" (bare frame, stripped lower), or some variety of NFA/Title II item. if the receiver is a frame, and you build it into a pistol, from the point where it is operable, it is considered a pistol. likewise this is true if it is built into a rifle. there is a narrow clause where you can start with a pistol lower, rebuild it as a rifle, and freely return it to a pistol configuration (
https://www.atf.gov/firearms/qa/can-i-lawfully-make-pistol-rifle-without-registering-firearm). this is
not true if the lower was transferred as a rifle, originally. it sounds as if it was transferred to you as a "firearm" or frame/bare receiver. this is noted on the 4473 paperwork for the original transferee if you would like to be sure. such a frame can be freely built into either a pistol or rifle, but you cannot legally build a short barrelled rifle without obtaining your tax stamp first - likewise having the necessary parts to assemble an SBR can be seen as "constructive intent", and the BATFE has prosecuted people for that.
the safest bet would be to assemble your lower and an upper into a legal pistol configuration if you want to try out a short barrelled upper. this would allow you to later choose if you want a pistol or rifle for that particular lower.