Sounds like the frame or the barrel are out of tolerance. Do you have a friend or gunshop with another Encore frame? If so have them install the 280 barrel on that frame. If the same problem arises, send the barrel back to Bullberry and they will take care of it. If the other frame works, send the frame back to TC and they will take care of it.
Just my thoughts,
Kyle
topboss8@yahoo.com