Looks like the tip of the delrin bolt pin is slightly rounded so is probably half the issue.
Also it only contacts the ramer at the top (possibly half the rammer diameter at best) so a redesigned pin could be the answer
Will raid the spring kit at work today to see if i can find anything suitable for a lighter poppet spring.
As for other materials then yes there are quite a few that could be tryed, lots of plastics are available in glass reinforced forms so would prove much stiffer.
We keep discounting ally but most other markers seem to get away with ally components without welding themselves together (Shocker, ION, Matrix, etc.) and magnesium is virtually as strong as ally but quite a bit lighter.
The issue with making a 2 or more piece rammer is it does get far more difficult to keep the tolerances and you start to get into issues with things comming apart. Threadlock seems a bit reluctant to hold on to delrin so short of superglue i'm not sure how we could stop things comming unscrewed.
What we need to keep in mind is that most of us shoot ego's because they are a high end marker that always works, things don't just fall apart and there are very few moving o-rings so with minor maintenance we have almost flawless reliability.
If there is a risk of something comming loose or whatever then i would rather find a differrent way of doing things (or different material) than loose that confidence that every time i pull the trigger a ball (or 2
) will come out the pointy end.