Couldn't the bolt be tapped so a heavier more stout bolt could be used? That was something I was considering later down the road.
Regarding the excessive muzzle blast, I had to shorten the hammer spring from 3.38" long to 2.7" in order to get it down to the velocity knee. That helped a lot..the pressure was dropping at least 15 bar per shot initially. Shortening the spring brought it down to about 10 bar per shot (~33% air savings) so that's a welcome improvement. When I reinstalled the end cap, I could see there's still a smidge of spring preload (approx 1/8") so if I get inspired I may try to cobble together an internal SSG for it.The regulator appears to be set to about 160 bar based on where the velocity begins to taper off.Next up will be an inspection of the barrel. If previous SPA guns are any indication, I'll have my work cut out for me.
Yes you really want to cut it back to completely remove the smeared lands. I have fixed quite a few barrels this way. As with most things, it’s no guarantee but most barrels respond with a dramatic improvement in accuracy.
If you have access to a lathe, could it be counter bored to remove the bad area and retain the threads?