1. The difference in range is because the angled range isn't an average. I fired twenty shots from each and took the average distance for the flat range. I then took the three darts that went over 100' (in the case of my Longshot) and fired those at an angle. I did this to find the maximum range. Other variables might be the angle I fired at. I fired it at a 45 degree angle which may or may not be the angle most people use to measure their gun's angled range.I don't see how the difference in your range with your angled to flat shots, that is not possible, or it doesn't seem that way. I have seen BBBs used as primaries, and 60 feet isn't very good for a primary, unless the ROF is amazing. My AT1K gets 65 (flat, I'm not shitting you) and the ROF is much better than my BBB. And where did you get that alluminum?
2. My BBB isn't my primary my LS is. The crayola barrel is just a temporary fix until I can get some brass, then I'm hoping I can get it to around 90'.
3. Actually, I'm not even sure it is aluminum. I found it in my house and I think it was part of a towel rack. It was originally 18'' long so I used the spare 8'' for the barrel of my now singled AT4K (I accidentally snapped a gear in half on the already broken rotation mechanism). The reason I think it's aluminum is because it's a silvery color and aluminum is a common metal so the chances of it being aluminum are high. I just hope it's not lead. If you're into buying stuff online, then you can find it on McMaster-Carr. If not, then I guess your best bet would be Ace.
Falcon, was that PJ? Also, don't the four brass barrels make the X-bow extremely front heavy?