A simple barrel sealing piston doesn't need O-rings. It just needs to fit good enough so that equalization is slow enough to actuate properly.
Just build the piston from moulding epoxy, fiberglass resin, hot glue, etc. No need to buy solid PVC rod. Just use your common sense though, weaker materials won't stand up that long.
If you still want to use O-rings, (hey, it gives more controllable equalization...), you might want to consider something I'm working on. For my barrel sealer, I'm just gonna extend the edges of the gaskets, (one on the front and back), past the edges slightly, (just slightly), with the gaskets securely glued and fastened to the piston faces, so that they act as a seal. I figured since BurntLatke pretty much used this idea for air-tight gasket slugs, it might work. If not, oh well. It's barrel sealing, and it's going to be exhausted by a 1/4" QEV. It's a double-seal, (front and back), also, so I think it has a good chance of working.
You can't just use the inside of a soccer ball for this sealing material though!
Order some neoprene sheeting off McMaster if you consider this idea.
I get all my junk in Monday, (I forgot UPS didn't deliver weekends, so I ordered on Friday), so if you want to wait a week or so to see if I can get it to work, go ahead. I'll share results when I finish the cannon.
Here's what I'm talking about.
<img src="
http://i10.photobucket.com/albums/a123/ ... etseal.png">
If this works, (and is completely airtight), I might use it on a chamber sealing valve to finally eliminate O-rings!!!