Hey there, we discussed some of this via PM, but here are a few thoughts for general discussion:
Parkerizing is done around 180-185 degrees F (at least the solution I use). I find it unlikely a properly fitted plug will "blow out" at those temps. That's not to say it's not impossible, but I certainly have not had it happen.
You can protect the inside of the receiver during blasting by inserting a properly sized dowel, rolled up paper, stuffing it with rags, etc. and using care while blasting. This will also work for painting. Speaking of which, painting would be the only way I know to protect it from the parkerizing solution without contaminating the solution. That said, I don't think it's really necessary (at least for parkerizing, paint is a different story because of it's thickness). I've parkerized two MKIIs and only painted (actually, finger nail polish) the feed ramps to shield them from the solution; both function fine post parkerizing.
The Rugers did require either massaging the process or post parkerizing treatment to get an even/close to even color. I say this because it seems the steel is different or heated treated differently between the barrel, receiver, and frame; thus they all react a little different to the solution which results in varying shades/color. Previously I would massage the process, but now i just dip them in a black oxide solution post parkerizing. The preceding is not a concern if you are painting over the parkerizing.
A lot of the "roughness" folks associate with parkerizing is from the surface preparation. Most often that prep is heavy abrasive blasting. Lighter blasting will yield a smoother finish.
If you are going to paint over the parkerizing, I suggest plugging the pin and screw holes. The sight cuts might also be a good idea. This will make reassembly much easier.
I'm with rugerguy, in that I prefer just "park" vice paint.
Here are some of my DIY parkerizing projects:
My latest
Regards,
Greg