Hi Philr,
all of my working fire pistons have an inner diameter between 10 and 7 mm. The pistons themselves are between 12 and 8 cm long and the tinder cavity is just a few mm (3-5) mm deep. When making one, I try to place the o-ring or wound thread gasket as far on the end of the plunger as possible without disturbing the tinder cavity. In this way the compression is concentrated predominantly in the tinder cavity. It is also advisable to give the underside of the piston and the handgrip on the plunger or piston rod an ergonomical (rounded) design to prevent sore hands
Charcloth works best as tinder in my opinion, tinder fungus (untreated
Fomes fomentarius, just very fine strips) doesn't give repeatable results with my pistons.
Good luck with your efforts,
Tom