Well, we found the problem. WadeS and I took his AR apart tonight and the spring was broken into four pieces. When it came out, it measured 9.5" long. When we arranged it the way it should have been, it was 13". Also, the pieces had wound their way into each other, creating a double-coil spring for about 1/3 of it's length. No wonder his velocities have been in the high 400's to low 600's. The spring seems to have been broken from day 1. The seal and cylinder look fine. $15 from PA should bring back mucho power.
Thanks BWANA for the advice on the trigger.