I couldn’t get your email to work so I figured I would post this here.
I took my Marlin apart and learned a lot about it.
It sure looks like you got it right the first time. Besides the firing pin on the bottom, the extractors on the sides and the pins and springs that go with them the bolt is one piece. It looks like you could drill the bolt without pulling the pins. At first I thought the "ears" on the back were just to add mass but it looks like they are the stops to keep the bolt from going back to far. The only other potential trouble spots I saw were the hole the recoil spring fits in to, the contact points where the bolt rides on the rails in the receiver, and the contact points on the bottom. It looks like none of these would have to be kept untouched, just keep enough material to retain their function.
On mine the bolt weighs 5.5 ounces and the operating handle weighed 0.5 ounces. I don’t know if that’s useful or not. I did notice the spring tension from the cartridge lifter (or whatever that thing is called) was a big part of the resistance against the bolt. I checked that by putting it back together without the recoil spring.
Separate from any modifications, I was surprised how much motion was in the trigger linkage and how unfinished some of the hidden surfaces were. I think after cleaning I will play around with mine and see if I can improve the trigger and overall smoothness of operation.
Lastly, there is probably no danger of this but please don’t get the impression I’m an expert gunsmith. You could easily listen to what I’m saying and still end up with a gun that doesn’t work right. I’m just a guy mechanically minded enough to like finding out how a gun works. It sure sounds like an interesting project. I would like to hear how it works out.