Details
Is this a STEN of original mfg., a kit gun from past legal times, a pieced frame, or what? We are talking MG, not semi, right?
I believe that the extractor is superfluous for the initial phase of bolt movement, but needs to hold tightly enough for the ejector to make a brisk impact kick for proper fling- just had a similar situation on a High Standard .22, needed to add a stiffer extractor spring for sufficient ejector action.
Chamber crud, rust of even minute levels, cartridge case varnish (WOLF crappage type, for example) can all add to the retarding of case velocity, and that is all there is to make that inertia bolt get moving against the spring.
Try putting a piece of tape over the bolt handle slot to gauge the travel amount, since the STEN is designed for overrun past the sear engagement travel point. Put a mark where that point is on the slot, and start with the tape to the rear of there, and move forward until regular contact marks the tape edge. Use this method to verify and compare various loads for operating power, but always hold the gun tightly and the same during such comparisons for the best and consistent results, since the gun has to buck against you as a part of the mechanism's designed condition of operation.
If you can fit a fired case carefully into the chamber and not get a sticky case condition, close the bolt on the case, and then activate the bolt handle manually, and see if the ejection happens as normal. Almost any gun can have a manual test of ejection, and only some are balky at feeding tests manually, like some Rem. 1100 types, for instance. Get enough bolt velocity by hand, the shell will fly free of the port.
Improper tip position, face angle, or other situation can occasionally cause an interference of the case against the lip of the ejection port, but not likely. I would rim the inside lip area with a magic marker to see if any strikes wipe off the ink.
Did you read the rim edge of the fired cases to see if any heavy scrape marks are present from difficulty freeing from the bolt face pocket during ejection? This is not likely to cause as much grief if any burr edges may be present on the extractor side, as on the ejector side.
Some ideas that may give you a "leg up", so hope that they help.
See my previous posts for some gunsmith perspective.
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