Dear azapa,
as the regards the corrosion on the barrel thread:
Has the threaded part of the barrel become brittle due to the corrosion?
If so, this would appear to be a serious safety issue and, hence, I would strongly recommend replacing the barrel before completing the reassembly and using the gun.
If not, i.e. only minor chips in the threading, I would go ahead with the reassembly and use the gun at low pressures (eg 15-20 bar) at first. In order to mend the the chipping I would use 3-5 rounds of teflon tape to seal the threading before screwing on the muzzle.
Actually, the Asso valve is similar to the Mares, Sporasub, Cressi ones, ie the all have a very wide slot. Initially I used a thick metal file. Now I use a ss pipe of appropriate diameter with a cross bolt. The front part has been cut and filed to match the slot of the valve.
Be careful to avoid cross-threading when you put back the valve.
Cheers
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