I ran 1500rpm at 25rps and 380fps on my 249, with triple torque gears, never had a problem with my prometheus piston. Only removed the second tooth on it.
Have you done a dry run of the cycle? Open your mechbox, remove your spring (but not the piston) and just rotate the sector gear and see if anything obvious is wrong between the sector and piston
FYI DO NOT USE POLYCARBONATE PISTONS
polycarbonate is inherently too brittle to be used as a piston material. And you definitely don't need more than 3 metal teeth under 420fps
Try using a nylon fibre (marui) or POM piston.
I've always had luck with prometheus style pistons, but they tend to only perform reliably when matched with prometheus gears.
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