Never needed to use heat to remove a barrel nut from an upper before. At most, my 18" breaker bar took care of removing the nut (when I had a wrench to go onto it). I did use a large pipe wrench on one that used a proprietary wrench that was unavailable, once. Still, never used a torch on any of them. Hell, even the PSA upper I recently applied Cerakote too just needed some more muscle applied to the adjustable wrench to remove the nut (didn't have a crows foot in the correct size at the time, do now).
How old is the upper that uses the old 'drop in' setup? I removed that from my first AR within a year (max) of getting it back around 2012/13. I think I've only seen non-free float handguard setups on the cheapest of cheap uppers in the last five years.
Did you use the old plastic clam shell upper holder with that? Could explain why you couldn't apply enough force to the nut.