The best prices on belts/ drums consistently are from numrich, but if you watch and are patient you can pick up killer deals on gunbroker or ebay occasionally. A few months ago I picked up a bunch of belts at $13 each on gb.
I do prefer the Saw pouches, but you can't use the 200rd saw pouches due to height if you're running a chopped bipod.
For optics the best is the factory polish swing away mount. They are very hard to get and kind of a pain to mount. I run a posp scope from kalinka but it has to have an ak mount, the svd mount is too low to clear the top cover.
You can't really put a optics rail on the top cover unless you mount it with screws and then the feed components get in the way. The top covers are stamped and when you weld them the tension of the stamping causes them to deform and they don't feed right afterward and are almost impossible to get to latch. (I've tried a few, they all came out bad even with very very low heat and light welds). There's a reason you haven't seen a completed project.
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There are no picatinny side rails for the receivers.
The dsa handguards look very out of place to me, but they are very solid and well made.
Barrels... DSA barrels aren't chrome lined. The original factory barrels were and the ones project guns had made a few years back are. The dsa barrels are good enough, the sarco barrels shoot well but are very prone to rusting in the bore. I think the sarco barrels were the only us barrels made that had the threads like the original design did.
If your gun is a factory built machine gun you can use the original barrel from another kit to re-barrel it but I'm not sure how many rounds it would take to burn it out. You'd just need a new set of bolt flaps to set the headspace with.
The original barrel is good for around two belts and then you should let it cool some. I've had a postie with an original barrel hot enough to smoke the cosmolene out of the wood before but didn't char the handguards. The only one I've seen really char the handguards was from an individual who ran around 800 rounds through one without a break and basically killed the entire gun.
Basically, if its hot enough that you're worried about the handguards you should also be planning to let it cool a bit so you don't burn the barrel out. If you do treat it with a bit of respect it'll last a long long long time. The postie I talked about before has probably 8-10k rounds through it now and still shoots as accurate as it ever did for me.
They very rarely break. It would be worth buying a kit while they are cheap so you have spares though. Over many years of dealing with rpd's I've seen a couple recoil springs collapse and require replacement, a few safety springs break, one bolt carrier actually broke (looked like a defect in the metal and cracked in two where the spent case ejection hole is). I've broken a few extractors tuning the gas for a suppressor(there is a spare in the tool kit).
I've worked on two that are owned by a shop as post sample rentals and they were choked with carbon (not sure what kind of ammo they were running but it was nasty crap). They were crapped up so bad that the carrier was being held out of battery by the piston.
You'll almost never find anyone selling the belts without the drums. If you do it'll be an individual on ebay or gunbroker. Load the belts from the end of the belt to the beginning. If the bolt closes on an empty link it'll mangle the belt.
As far as suppressing them, yes its doable. I have a gas regulator I welded up and then ground out just enough to run suppressed. There was a run of thread adapters done years ago for these to mate a 5/8x24 suppressor to the factory metric threading. They don't suppress that well but they aren't unpleasant to shoot either just a bit loud. I'd be very weary of putting a suppressor on an original barrel. Some of the original barrels have the bores pretty far from concentric to the threads.