There are several people on this forum that are much better at genetics than I am. I'll probably insult a few by mentioning specific ones and leaving some people off but Tadkerson, Henk69, Rareroo, and Sonoran Silkies immediately come to mind. All of them seem very glad to help people. I'm not personally going to suggest drastic changes because I just don't feel qualified to make that recommendation. Hopefully someone that feels more qualified will add their thoughts.
You seemed to think it was not from a buff brahma bantam. Even though the chick was the same size as the BR chicks and did not have feathers on its legs does not in my mind rule out that one of its parents is from each breed. The way I understand it, the chicks from a bantam-full sized cross could take their size from either parent or be somewhere in between. I'm not sure how leg feather genetics work, but again a recessive is all it takes. And the buff color can be made from several different gene combinations, most of which are not strongly dominant. I don't know what the specific gene combinations would be, but I could see a buff roo over a barred rock hen, the hen (and maybe the rooster) having a recessive gene, that might explain that chick's color. And a good barred rock rooster over that hen would always give you a barred rock looking chick.
If you got the chickens from a breeder, I'd suggest going back to them and discussing it with them. They'll probably be interested and may have a ready explanation. If they came from a hatchery, there is no telling what is in the genetic makeup of the chickens. Some recessive genes can be hidden for generations.
Did you get any solid black chicks from either hatch, solid black in the adult plumage, that is, and especially solid females. If you did, that will be a strong indication that the flaw is in the rooster's barred gene. Or at least one of the flaws.