What kind of velocity increase do you get over the 22-250 Rem with the AI version. Also do you just fireform 22-250 brass in the AI chambered gun? Or do you have to use a die to form brass?

depending on bullet weight and barrel length, I would gain 2-300fps with my AI. as for forming, just fire full-house 22-250 loads in the AI chamber and voila... One thing I did if I didnt use a STOUT load for fireforming the subsequent loads in the brass were never as consistant. I liked useing 38-39g of H380 with a 55g rem psp for fireforming. It would hold .75 in with an occasional flyer.

My Rifle now is a 22-250 Rem VS with a 26" heavy barrel. Current load is 41g's of H380 behind a 50g bullet. Hows the effect on barrel life with the AI?

I used 22-250 winchester factory rounds in my 22-250AI and 4 out of 5 came out with split necks.Head space checked out fine. Used some Norma factory rounds and all came out with out a problem.FWIW

barrel life is good if you maintain it.... KEEP IT CLEAN.
also, don't do a lot of heavy loads without letting the barrel cool some especially with ball powder. my pet load was around 41g of varget with 55g nos or hdy ballistic tips. I had good luck with 40g hdys as well. my first barrel was a shilen 1-14 and the second is a hart 1-14 both of them were finished at 27.5in. in the latest configuration it weighs 15lbs without a scope