Ok, everyone, as promised, here are my results.
(edit: couldn’t quite figure out posting the images directly, so here is a link to the online album)
https://photos.app.goo.gl/gbTxcjyZBs81vKEK8
When I unscrewed the cap, I could hear the spring inside making spring-y noises. Not so important but I will contrast this later.
As the images show, the plunger looks to have quite a bit of some kind of corrosion on it. Covered in white stuff and quite discolored in general. All except for one part that looks to me like copper, which I believe is where the spring was resting. I can’t say that the material looks nickel coated, but it is a little hard to say given the state it is in. Personally it looks more like copper (given this exposed spot) coated in brass, if that makes sense, but I’ll let you judge from the pics.
The spring is also coated with a lot of white stuff, as you can see in one of the photos. Not sure what the spring is made of. I guess I would have hoped stainless steel, but since it was coated with white crud I’m guessing not.
Anyway, I cleaned them off the best I could, lubed the plunger metal (and top o-ring) with Molykote 111, then put it all back together. I screwed in to right where it was previously (had made a mark with permanent marker on a thread just outside of the screw-in area); no spring-y noises as I rescrewed.
Upon heating and engaging the pump into a blind basket for the first time, the pressure did NOT spike, but only went to around 7.5 bars! But, upon a second run, it went to basically the same number, so that was promising. I had to screw the top of the OPV in significantly more than it was previously to get pressures up to more reasonable numbers, and now it seems to be at around 9.5 bars with the blind basket and current screw-in point. So far, it seems much more consistent shot-to-shot; I’ll report back on this specific point tomorrow morning after my first shots of the day.
Fingers crossed that this has at least temporarily fixed the issue. I would love to not have to do this again, though, as re-assembling the OPV was a little tricky, since you have to keep some pressure on the end while trying to engage the threads without cross-threading. I guess if it’s once every few years, I can live with that, if there is no more permanent solution available.