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Throughout these trials, I noticed that the tappet plate "fin" doesn't seem to have enough clearance for the selector gear nubbin to travel around completely, without bending (arcing up) the back end of the tappet plate. I found this odd since the tappet plate should run straight back in rails molded into the mechbox case. I took just a little off the tappet plate fin to give a little clearance.
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Bending (arcing up) which way? Like, towards you (up and away from the gear)? If it's only up and away from the gear, that's normal. All you had to do was to shift the tappet forward until it cleared that rod on the gear or rotated the gear until the rod is not underneath and proping up the rear of the tappet.
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2. I've noticed that, fully assembled, that the nozzel does not return to the fully extended position, but rather to a retracted position. When it fires, the nozzel will move forward and then aft again (almost like an open bolt SMG). Not having another v3 mechbox to compare against, is this normal? I would not think so. Could the tappet plate be jamming and sticking rearward?
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That's normal, no need to worry about it.