Machinist problem

So here is this little issue I am struggling with. Who knows, maybe someone here has the skills needed..

I have been trying to make some custom 6x32 tpi bolts for an old Belgian Bulldog revolver (about 1880ish). The original bolt bodies (frame mounted) are full of corrosion pits on the shaft and also someone without the right tools had managed to burr the screw heads at some point in the past.

The bolts are tiny and under magnification I suspect the threads were cut by hand. Just a tad under a #6 in size about 0.62 long. 3 of them. So I retapped the right side holes in the frame to #6x32. That was the easy part.

Only the bottom .197" has threads. Then the body has a smooth 1/8" shaft with a screw head size of 0.15".

I am using a steel 3/16" rod. I can usually get things down to about 0.155" before problems begin. When I use a steady rest (or a drill chuck in the tail stock) somewhere around .135" either the rod begins to bow or (worse) it just snaps in two. If I loosen the rest naturally the rod bends.

I know it can be done and hopefully without simply using just a file and sandpaper (which would probably take longer than I have years left).

I am using an HSS cutter which is giving a decent finish so I am confident I am okay there, but how to stabilize things so the rod doesn't snap or bow under cutter pressure remains the problem.

Yes, if I owned a monster press I could maybe swage it through a hole. But I don't have that.

I am of course also looking forward to the idea of putting threads on a part that tiny.

Open for solutions..,