Items to examine
Donald,
You are correct in your assumption of the gas system operation and of course it also cocks the hammer. Items to look at, for you, are carrier weight, buffer weight and action spring length. You don’t mention barrel length, port diameter or location, so the items above are the things to examine. Some carriers are substantially heavier than others and will delay unlocking too long for your light pressure rounds as will a heavier buffer. By reducing the weight of both of these components and shortening the action spring one coil at a time, you may get the bolt to cycle correctly.
I'm assuming that the bolt is at least unlocking and starting back. If it's not doing that minimum amount, then your friend needs to build a dedicated upper for subsonic use - moving the gas port aft and increasing its diameter.
Please ensure the gas port is not partially covered by the gas block - it wouldn't be the first time that's occurred.
Going to the heaviest/longest bullet possible with his present twist at the same velocity, will require more powder, which will increase port pressure. This will help cycling.
Another area too look at is the carrier's finish, on the bottom. Some are rough as a cob and will retard bolt movement. Ensure that the portion of the hammer that the carrier strikes is polished, as is the carrier.
I built a 6mm PPC for a gent who insisted he wanted the gas port 4 inches up the barrel from the normal location. Rough calculations indicated that this was going to cause cycling problems, because the port pressure was too low. By employing the techniques outlined above and going with a gas port diameter of 0.1065 (normal for a 223/220/6mm is roughly 0.0935) I was able to get it to function satisfactorily. The cycle time could be measured with a calendar, but the recoil from a rapidly cycling bolt was dramatically reduced – which was his original goal.
Good luck,
HPC