Thanks for the assistance

Sorry for your troubles Gb. I'd start around 125 bar on the reg. Another stab at it....possible pellet clipping? You could try a string with the shroud off and see what happens. Nothing to lose at this point. A cracked air stripper or bad oring up there may cause just enough mis alignment to make it clip. One other thing, and probably not enough to cause your wide velocity swings. My 25 would lead up real bad after only a couple hundred pellets down the barrel. And nothing but a bronze brush would clean the lead out. Hope you get it figured out.
 
I don't believe it matters how the hammer is inserted. The groove is not aligned to anything that I know of. I believe its all free floating. You can pull one of those hammers and just randomly drop it back in and it works. My Wildcat had the chipping on the hammer as well and I think it was caused my improper adjustment of the trigger linkage/pellet probe. I know there's a rule of thumb on setting the pellet probe depth but that's if the air tube is clamped back down in the exact position it came from the factory. If the air tube clamps are ever loosened which allow the trigger linkage to change this will affect the probe depth as well the the cocking of the gun when you go back together with it. You might find that it won't cock and hold at all or it will be very light. At the same time your velocities will very inconsistent and more than likely low all together.

Mine was giving me fits until I figured out what was going on. Anytime you loosen the air tube clamps it needs to be marked very precisely or take some measurements with a caliper.

Just a guess, what might be causing the chipping is the hammer flying back and hitting the trigger sear that may not have fallen out of the way due to the linkage being "out of time". I don't know this for a fact but it has to be something on the back side causing the damage and the first thing that it would hit would be the sear. I cleaned mine up in a lathe. If I hadn't had it I would have just ordered another hammer.

Hope you get it back to shooting like new again.

jk


 
Glad you got it going your way. Just wondering if the cocking rod/pellet probe adjustment being way out of wack in the past with the previous owner might have been a large part of the reason. I know I didn't have any misfires with the lever not fully closed but if the lever and and probe are out of adjustment it'll think it's ready but inside it really wasn't. I found the damage on mine after I had my apart and had things out of time for a while. Live and learn.

I'm surprised your gun had that heavy of a hammer weight in it. The MK I 25's just used a 177gr but my Royale that was at one time unregulated had the 195gr in it. I guess due to the higher pressures a unregulated gun encounters. Was it the weight that was in it when you got the gun?

Jking