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Not exactly an NFA discussion, but...

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PC13:
I think most of your concerns could be addressed with ammo selection/bullet weight choices.   Lots of good reading out there for googling.  I'll see if I can find you some links.  You're going to sacrifice roughly (very roughly, lots of variables) 100 fps for every inch of barrel reduction. 

The dwell time issues can easily be mitigated with buffer weight testing or an adjustable gas block.  If/when you choose to SBR, there's the A5 system to help with reliability, too. 

I agree with your barrel length choices.  I think 10.5" is the minimum I would choose as well and I personally prefer my 11.5 over the 10.5.  I think it's the best balance for all your stated concerns. 


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bkoenig:
My 11.5" was pretty overgassed (and REALLY overgassed when running suppressed) but an adjustable gas block tamed it down nicely.

PC13:
Dan, this might address your concerns about SBR/Pistol performance.   Didn't know this was on the market and haven't used any, but you can decide for yourself if it interests you. 
http://www.hornadyle.com/products/rifle-ammunition/556-nato/75-gr-tap-sbr


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Dan W:
I decided to go with a Faxon 11.5" Nitride barrel with a midlength gas system
http://faxonfirearms.com/11-5-big-gunner-5-56-nato-mid-length-4150-qpq/

Somewhat of a new concept, but I have researched it enough to convince myself it is viable.

I am also going to use an SLR Sentry 6 gas block to fine tune the gas system when I eventually get my first suppressor.

My plan is suppressor next and SBR stamp after that cuz my tax refund is all used up

shooter:
 very nice looking barrel, that gas port is huge,  but a adjustable gas block should be good.  I know they tested it, but that gas port is really close to  the muzzle, I was always told you need 4 inches of barrel  past the gas post.

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