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I d agree here, alignment of the barrel would be really tricky.

You will note that there is no optimum barrel length for a cylinder volume, there is a range of ratios and this is because of the other variables, air pressure loss and starting pressure, BB mass, hop setting, barrel bore and general quality. Also what your goal is for the system. Ratios quoted...

The spring is very much the limiting factor, if you could use another stronger spring I'd guess the gears and bearings would give up. 

Check out begadi, they have flektarn stuff of various types even tho they are over seas. Ive ordered from them without issue.

Life batteries are great, their main advantage is that they don't self sustain a fire like lipos do, you need extra outside heat to get them to keep burning after you have stuck a nail through them and they are also more tolerant to charging or discharging abuse. They work fine in airsoft guns...

I've had no batteries catch fire or explode, except some nicads back in the 70s which overheated exploded and melted some carpet, in 50 years. I store my batteries in ammo boxes partially charged nowadays, but before that just looked after them, threw away the puffies or physically damaged ones...

Air pressure behind the BB is probably the most important criteria for stability in a barrel. Enough to push past the BB and stabilise it. Longer barrels will need the same pressure for longer and shorter barrels may other issues of their own like insufficient time to stabilise or excess...

It is easier to hold a lighter weapon steady than a heavier one, the addition of a shoulder stock to a pistol is a great bonus to accuracy. It's not about the barrel. Barrel length and bore don't affect accuracy until they are at extremes. BBs don't rattle around the barrel on the way down...

Not all spring guides will accept a bearing, Lozart is correct about bearing sizing and simply bearings I have used alot for pretty much all my bearing needs. Fit a bearing at the head end if you can rather than on the guide.

The corrosion occurs all over the contacts, not just on the parts that face you. Gotta take it apart to see.

check for corroded contacts in the cap and at the base of where the batteries live

You haven't cycled the gearbox with the receiver off have you? Just run the motor? I was thinking you had cycled the gearbox... I would do this and observe the cut off lever and the trigger trolley, check the trigger itself catches the trolley again.  The fire selector plate if it moves ok...

Look at the cut off lever and fire selector plate. These together with the trigger trolley allow single fire. Otherwise you'd get auto all the time. The receiver can pinch both the fire selector plate and the cut off lever. Is the fire selector controller installed with the receiver?

Gbbrs have the advantage of a reservoir of gas to keep the pressure up until the BB has left the barrel. This means that a heavier BB will continue to experience the same pressure as a smaller BB but for a longer period of time and so gain more energy. Since the pressure is maintained after the...

Take off one of the spring bearings if you have 2. There's no reason to have 2, and you will reduce the preload by doing it. Either you've assembled the gun better this time or the springs are not rated correctly. You shouldn't be seeing that much difference between the springs altho the rps...

if you are getting 28rps that seems ok, you are probably being limited by the battery. I unsure that you need all the things you have in place. If you had PME you'd be hearing the gun chewing itself to pieces. If you are losing fps on auto its, to be expected to a degree, but you might be...

Use a hole saw on some sheet perhaps

If the current bucking is hopping whatever weight bb you are using, properly then it's fine. You'll be seeing similar fps at the hop as everyone else, the weight of the bb will matter more and you should have plenty of adjustability to offset the increased spin on the bb.

Web based calculators for me, faster by a long way and no typing if you use voice in google or any of the other assistants if you are after converting one thing to another. Excel is not really for this kind of thing, unless you always have it open or are automating such conversions for some reason.

These sort of springs are plated or they are stainless and once the plating has gone they will corrode really quickly, altho silicone grease will delay this if you lather it on. The caps can be disassembled and new or replated springs installed. If you cant get the springs out from down the...