After some test firing, the AK.45 still will not eject properly. I examined some of the spent casings and noticed that there was virtually no mark from the ejector on the head of the case. There is a small triangular mark, but it is nowhere near as prominent as it should be.
I removed the carrier and inserted a spent case into the cup. I rotated the case until the mark lined up with the ejector slot. The ejector needs to be making much more contact with the case. The impact mark is circled in red.
When my welder attached the bolt to the carrier, he had the bolt turned slightly. It wasn't exactly square, but was easily cleaned up in the mill. This resulted in the ejector slot being turned down at an angle. To get the carrier to clear the ejector, I had to bend it (the ejector) down a little. The ejector is bent down too far to make proper contact with the case during ejection. The case just barely makes contact with the ejector, so it just sort of bounces around in the receiver instead of being thrown clear. With the ejector tip so far down, the case also flips up into the gas piston extension.
To fix this, I will need to recut the ejector slot with a woodruff cutter. I will need to bend the ejector back up to get a good contact. This should fix the problem and get the thing running 100%.