It's been done. But keep in mind, you are fighting physics here. A std extension is already only about .0625 thick at the thinnest place, IIRC, so there's not much room to open it without creating a new weakest link. Bottom line is, smaller case heads produce less bolt thrust as do lower pressures. Some people are simply pushing the capabilities of the ar15 platform, for reliability. Frankly, it was bound to happen with the 6ARC. It was already happening with 223/556 stuff but the increased bolt thrust with the larger case id is exasperating and exposing the inherent weakness of the ar platform. Great gun..but we are at it's limits without significant re-engineering. In no way am I badmouthing an ar15. It's just that we are at its limit with a larger case head. It's not that the bolt head is thinner, its that there is increased bolt thrust any time the cartridge case id is increased. But to your credit, you do seem to realize that rather than blaming the bolt design. The platform just has limitations and it was a bit over built for its original 556 cartridge but not so for the larger case head of the grendel based cartridges. I don't see a reliable solution other than to accept it for what it is or to step up the bore size, ie a 30 cal, due to lower pressures with the same case and bullet weight to make the same speed with...at the cost of ballistics.
The problem is not the cartridge and it's not the gun. It's this cartridge, in this gun, due to the inherently higher bolt thrust. We can not and should not expect the same cartridge max psi when the bolt thrust is increased with a fatter case. It is what it is.That said, the ar10 can now be aquired in a gun that's about the same weight and you won't have this same problem in that platform and at these pressures.