The remaining part of the o.d. was turned down .1 just enough to clean up good.Meaning the 3.5" diameter is now 3.4"?
I, too, think your breech plug should be longer, like 2.5" or so. In fact, I prefer screw in plugs so they can be removed and fouling cleaned out of the joint between the tube and plug.
You could have multiple sleeves like the
Brookes.