Some years back (way back) a similar problem occurred with the early guns made by Uberti and imported by Navy Arms. At the time, Navy was "THE" importer of reproduction Henry, 1866 and 1873 Rifles. The guns were coming out of Uberti over polished with rounded over edges on the barrel flats. Val Forget made a trip to Italy and demonstrated how to polish and octagonal barrel on a belt machine to preserve the sharp definition of the barrel flats.
Quite possibly, the folks at the "new" Henry, need to learn the same technique. Buffing an octagonal barrel with a common rotary buffer just doesn't work well at all.
I would expect the Henry folks to take notice of this and correct it toot sweet. Now, if I can just get them to build me one chambered for 44 Russian, I'll be some ecstatic. I'm not, however, holding my breath. I would settle for .44 Special. Set up for .44 Russian is really easy.
Coffinmaker