I had made a lead seal trimming fixture for the lathe to shape the seals to the correct size and shape. Makes assembly sooooo much easier, (less chance of cross threading the internal threads on the plug that fastens the valve body in.
Some good reading here: http://cinedux.com/challenger-arms-corp.php https://www.tapatalk.com/groups/americanvintageairguns/viewtopic.php?p=67905#p67905 https://www.tapatalk.com/groups/americanvintageairguns/viewtopic.php?p=53922#p53922
Between my son and I, we have a couple of Plainsmans, to include the .28 shotgun. Need to rework the valves on the Co2 and some multi-pump ones yet, (life keeps getting in the way).
Chem milling has been around for a long time. If you were to paint the ID of a barrel with the chemical resistant coating in the twist pattern you desired, you could just put the barrel in the tank for a set amount of time and be done.
I have an Avenger that I fill by hand pump to 3800 psi, with reg set at 2100 psi. Refill when it gets to reg set point, (2 sets of 50 strokes each). But, I have gone through my pump to make it more efficient. Works for me.