No, my CYMA AK is so tight around the gearbox that it can be a bit of a bugger to get the thing back in and seated horizontally. I dab a bit of grease on the inside of the receiver. It's plastic though, so I expect that if I stuck some really thin rubber sheet to the inside of the receiver, with a good dollop of grease it would probably fit, but that would make the battery tray assembly even more difficult to seat with those poxy little angular hook-thingies in place properly. I dare say that the design works a treat made from a decent metal, but made from plastic it's an arsewank waiting to happen...
No, I don't know that all airsoft suppressors are completely useless, just that the foam inside them is the next thing to it. Even a single chamber suppressor will have some antiphase subtraction effect. Something that the foam would work at though is to hold some washers in place to make chambers inside a suppressor.
If you could find some washers big enough around the circumference to fit closely to the interior circumference of the suppressor, with a hole say 8mm in diameter (unless the washers jam tightly against the interior (in which case no foam will be needed), they will slip down so that even a 7mm hole might not be big enough for a BB to pass through without clipping the washer), you could cut the foam into say 4 unequal lengths and fit 3 washers between them. The thing is that internal chambers which aren't completely sealed would have less effect than sealed. Without testing I couldn't really guess, but the difference could be so much as to make doing it pointless unless you could make sealed chambers inside.
If you've had a busted cylinder head I'd guess that something was pretty drastically wrong inside the gearbox, but the absolute best thing you could do to quieten an AEG is cushion the impact between the piston head and the cylinder head, so if you've got it apart perhaps that's something to think about? Is it an AK? I ask because Element make what they call a 'Silent' piston/cylinder head combo, but as far as I know it's only available for version 2 gearboxes.
Something I have tried is fitting a rubber washer to the inside of the cylinder head, but it didn't do much. I think the rubber may be either too dense, so the energy is passing through it as well as it would through the plastic cylinder head, or not dense enough so that, because it doesn't reach right to the edge of the interior circumference of the cylinder, it's squashing so easily that the edge of the piston head is connecting with the corresponding position on the cylinder head pretty much unimpeded. Doing this did alter where the piston comes to rest however and I think it may have something to do with a recurring problem I've had with teeth coming off the sector gear... (but maybe not, because where the teeth come off isn't from the part in contact with the piston teeth).
I've just bought an airbraked piston head to make my AK quieter though. Ed has one in his L85 and it is nice and quiet -
Lees Precision Engineering
Haven't got round to fitting it yet, but I have high hopes
PS - if you're having trouble getting the trigger back into a version 3 gearbox, I do it by assembling the gearbox without the trigger and that little slotted swivel-thingy. Then, holding the part containing the gears together as tightly as I can whilst cracking the front part of the box apart, I push the trigger in so that the left hand side pin goes into its hole. Doing that then allows me to pivot the trigger forward trapping the spring against the gearbox shell. Then that swivel-thingy left hand side pin has to get inside the box which means that the rear of the gearbox has to come apart a fraction more. In 1 smooth motion use a trigger pulling motion whilst simultaneously rocking the trigger up towards you (the right hand side of the gearbox) and the swivel-thingy pins and remaining trigger pin will drop into their holes without allowing the spring end to ping out...
practice mate
I also use a thin sliver of steel to help hold the gears in position when I first close the 2 halves of the shell - it makes the job work 1st time more often than without it, but I'd say I'm an expert ver 3 dis/assembler and I wouldn't bet much on my ability to get it right 1st time - that 'kin trigger spring has a mind of its own sometimes it seems. Another trick is to use a good blob of grease to hold the spring in place so that it doesn't fall off the trigger pin as you bring it up against the gearbox.
Gearbox sliver-tool: