kingfhb:
1. I considered removing some of the material from the front of the pivot pin upper receiver housing but being that the 15-22 receivers are polymer and not knowing enough about their strength I opted not to. I considered that the gap may just be the result of the "stacking" of tolerances between an airsoft replica and the handguard adapter. Even the authentic NSR has a gap on most installs. Please see picture below.
2. I'm really not too concerned about the gap and it's practical effects as I don't expect to utilize optics which have mounts that span both the receiver and handguard. At most I would use a cantilevered mount from the receiver only. The only optics I've seen that would span across would be something like an Eotech 512 or 516 and I believe those only have two cross pins which I would put fore and aft of the gap. I only intend on putting a flashlight and a folding front sight on the handguard. The gap will have no effect on either of these especially with the front sight having an elevation adjustment and rear sight a windage adjustment.
3. I was also concerned about this, and with this particular handguard being a replica, I reverted to the original to search for details. The authentic Noveske NSR attaches the same way, albeit with a different barrel nut. The authentic NSR does have a provision for an anti-rotation pin, but to use it you must either drill a shallow hole into the front of your upper receiver to take the pin or use one of their Noveske/Vltor upper receivers which are pre-drilled. However, users that have not utilized the pin have reported no problems with the handguard rotating. Consider that to install the barrel nut, you must use a wrench perpendicular to axis of the rifle with the additional leverage that a wrench would provide. I personally would not be able to provide that much torque using my bare hands when holding the handguard along it's axis. Additionally, with the operation of the action being straight backwards without any twisting motion and the low recoil of the 22LR cartridge, I don't see how any vibrations would overcome the at least 40 ft-lb of torque necessary to begin loosening of the barrel nut.
tomcatt51, The small height mismatch is an illusion of the pic. The screw holes to fix the handguard to the barrel nut are large enough that they provide some movement. When screwing in the handgard onto the barrel nut, I placed my primary arms red dot spanning the receiver and handguard to line it up and prevent rotation as I tightened the 6 screws down. I had no problem placing the optic here. After the screws were tightened down, I moved my red dot back to its original location.
This is a picture of a real Noveske NSR on a real AR15 receiver: