I was also thinking of checking home depot for an appropriate crush washer to fit the OD of the barrel ahead of the threads as well as the ID of the flash suppressor castle nut window. Starting to get a bit over-precise for home depot though, and a hardware specialist like Copper State Nut and Bolt would be better. Good to know my idea wasn't out of line and someone else thought of it.
kgb: I removed the entire setup by hand, aside from the stop-bolt (used an allen wrench for that obviously).
When re-attaching the castle nut, I tightened by hand until I could go no more, then finished the remainder of a 1/8 turn (just enough to get the next full castle nut recess in line with the stop-bolt) by gently tapping the castle nut windows with a punch and hammer. I think I ended up needing to turn it about 5 degrees that way, was all. No deformation of the castle nut.
The only issue with using it in this way is that it's soft. And the flash hider will still wobble, and the tape will grind down over time, leaving you loose again. Red loctite is probably a better answer since it at least lasted this long.
It has no wobble right now, so I guess it's a "good 'nuff" solution for now. Definitely better than it was before. At least a hundredth or two of an inch lateral wobble was visible and audible. Being that it's soft, that means it must be somewhat elastic as well, meaning any give in it will end up attempting to return back to a center point.
Do you think I'll get better rigidity by tightening one notch further with castle nut pliers? I'm willing to get some, but I have Walt Kuleck's M14 book here next to me and it suggests to not overtighten the castle nut.
I'll ask the guys at Smith Enterprises about this problem next time I'm down that way, and see if their new manufacture flash hiders rectify this problem.