Jim,
You bring up a very good point. There is a slight amount of rotational play between the bolt and carrier after the bolt moves into full battery. If the front sight base needs to rotate 0.030" clockwise while viewed from the rear sight and the receiver slot the gas tube passes through only allows me to move the front sight base 0.020", I'll remove 0.010" material with a pillar file from the side of the slot. I cannot remember ever removing more than 0.015" or so and that was only on one rifle. Many times on a problem rifle, when I view the gas tube while looking through the bottom of the upper receiver with the bolt locked open, I'll observe the gas tube is off center with the barrel being indexed too far counter-clockwise when the barrel was installed. That would be the direction the barrel would move when the barrel nut was tightened at the factory. I would also notice a slight amount of binding between the gas tube and bolt carrier key when slowly cycling the bolt.
If I remember correctly, moving the front sight clockwise 0.006" shifts the Point of Impact a little more than 1 Minute of Angle to the left on a carbine, so a 0.030" front sight shift would move the Point of Impact about 5 MOA. I haven't had a rifle that I adjusted be more than 3 clicks windage from the zero windage mark on the rear sight assembly after re-indexing the barrel without removing any material from the receiver slot. I always check for smooth engagement of the bolt into the barrel extension before firing the weapon.
Even when installing a new barrel on an upper, I always take the extra time to hold the barrel with a wood dowel rod inserted in the front sight base and keep the gas tube centered in the slot on the upper receiver. A majority of the time my zero won't be too far from zero windage on the rear sight assembly. If your measurement indicates you have to move the front sight considerably more than the upper receiver slot would allow, you may have to purchase a new front sight base with allen screws and make your adjustment that way.
A critical area to check is the gas tube to bolt carrier key engagement/alignment. The engagement should be smooth without any indication of binding. Any binding will cause malfunctions.
If I were Arty Fo I would remove the UTG sight, borrow a detachable carry handle, attach it to my rifle and shoot it before I made any changes to the upper.
Hope this helps.
Charlie D