just to be clear the mechbox and spring guide are designed with 2x positions
- position 1 - where the spring guide notches are aligned
- position 2 - spring guide fully forward (as its seen in the pictures)
so the piston is not jamming on the guide, and yes i have run the gear box with out the spring in it many times (I ain't that dumb

)
in any case I have a feeling it has something to do with the wooden block that's throwing things off balance.
the stock ares part had about 1mm of contact on the spring guide whereas the wooden block touches the entire thing
I shall try ordering a spare from direct from ares