The biggest gun malfunction I’ve seen wasn’t mine, but it was a sight.
I love the Browning A-5 shotgun, and the ones built on the same patent like the Remington 11 and Savage 720. The damned things just work.
For a little while, there were two of us using them in 3-Gun around here. I used (still have) a Rem 11 that’s been shortened, mag extended, etc. The other guy’s was a Browning I think, but might have been a Rem 11 also.
As I said, they work. They slam any ammo into the chamber and throw it out like the empty shell is another weapon. Rain, sleet, snow, blah, blah, blah.
Until they don’t.
I don’t know the cause and he may not either, but his went down HARD one day. He had knives and big screwdrivers working away trying to get two shells (at least) torn out of the gun. Trigger group was out. Shells were cut up. Number 8 shot, wad material, and powder was everywhere.
He kept taking pieces off the gun and cutting away shells until he got it cleared, but that was the ugliest malfunction I’ve witnessed.
Dishonorable mention due to cost goes to a couple of SMG malfunctions at Knob Creek. It wasn’t exactly uncommon for someone to get a light load whose bullet wouldn’t leave the barrel but would drive the blowback bolt far enough back to pick up another round. In a fast-cyclic gun like a MAC-11, you can’t get off the trigger fast enough, and the bolt might not come back enough to catch anyway.
Brrrrrp. Sudden stop. Rupture. Destroyed SMG. Maybe the barrel only if lucky, but luck didn’t play into it much.