I've got a Springfield rifle which is basically the same as the FA91.
I have that same issue with excessive gap in the cocking tube such that the charging handle doesn't properly cam open the bolt.
The problem is the cocking tube is welded to the front site triple tree, so the problem gets worse as the gun gets hot.
I seam to remember that the FAC guns might have it attached differently with glue or something in the receiver, which isn't going to hold up anyway.
Take the bayo plug or dust cover off the front sight, and look down the center of the hole in the triple tree tree to see if the cocking tube is welded to the inside of the triple tree, or maybe the outside of it. It it isn't attached in any way at the front, its probably glued, epoxied, pinned, whatever (but not welded) into the receiver at the rear of the cocking tube. As so, it probably worked loose over time, or if your heaspace decreased, then the carrier going further forward might have pushed the cocking tube forward. There is no good fix for that. One of the problems with that aluminum receiver design, the tube is meant to be welded to the receiver.
As far as the recoil problem: headspace, recoil spring, buffer. Who knows what the previous smith did, so start from square 1 and check it all.
As others have said, the only way to make the gun right is to move all the parts to a steel receiver. Most of the those guns were built with nice FMP parts that would make a great gun when rebuilt.