Looks like the error was confined to an early version of my combining of my infantry weapons to TW scale and my infantry armor kits to TW scale conversion sheets.
Found the link. Yay! It's not what I was looking for though. I was looking for something that says how much damage per weapon is done per round to BAR armor and in TW.
Riflemech:
1) It depends on what you're playing. Are you playing AToW or TW?
That's just it. There shouldn't be one of the other as you should be able to go back and forth. Right now an Auto-Rifle in AToW is far more powerful than one in TW. And that's not including the fact that AToW turns are twice as fast.
2) Here's how heat transfer works (I am, in fact, a physicist): good conductors (like brass) transfer heat quickly. Quickly enough to transfer it to the block, and the outside of the casing (meaning they both feel hot after a shot). Poor conductors transfer heat slowly, meaning they absorb more heat into their mass and only slowly radiate it outward. This means a plastic (really, composite) casing will absorb more heat into itself, and only slowly transfer it to its outer surface, and thus the block. This is why both the block and outside of the casings feel cool to the touch immediately after firing in the video. Am I making sense yet?
Sorry. Went right past me. If the casing is a poor conductor of heat, how's it remove the heat?
3) I haven't read anything about 5.56 composite rounds, so I'm afraid I can't answer that question definitively, but I believe most current 5.56 rifles have sufficient overengineering to be able to fire at least SOME rounds before requiring replacement.
The video mentioned them but didn't show them in use. Single shots makes sense. Warning labels "Do Not Fie At Full Auto" makes sense. Their being made backwards compatible so the older guns don't blow makes sense. A warning label, "Not made for these firearms with a list." makes sense.
4) Link as requested: https://bg.battletech.com/forums/fan-designs-rules/fixing-the-atow-companion-conversion-to-tw-for-mech-weapons/msg1709504/#msg1709504
Thanks!

Unfortunately, I can't open it with the good excel. The new one does but I can't do anything. Not that I understand it.

It doesn't seem to be what I'm looking for either.

5) At least one point got through!
WhooHoo! Where's my donut?

So how do we handle the M240 and other weapons where parts are changed? Same everything but amount of ammo?
6) No, not right. As I explained above, the composite casing absorbs more heat into its mass vice conducting it to its exterior surface, and thus the gun. When the casing is ejected, it takes all that absorbed heat with it, and that is MORE than the brass carries with it.

If the casing is absorbing the heat and taking that heat with it when it leaves, how can it transfer it to the gun? And why isn't it hot?
Watched the video again. It said that the polymer is an insulator more energy is used to push the projectile. They use 10% less propellant to do the same job. It's about 7:50 minutes in. That would explain how it's backwards compatible. Less propellant used for the same job.