a. As I keep saying, portion working west of Plymouth was a fact of life pre-HST, so no first class or catering at all.
Why are you talking about first class or catering?
Portion working with loco hauled stock is an entirely different matter to portion working with non-corridor EMUs that expend significant volumes on the end portions.
And there was no technical reason that BR could not have built short HSTs with multiple working jumpers, and yet they didn't?
Why didn't they if portion working is such a wonderfully efficient thing?
Former senior BR manager Theo Steel says in an article about the railways in the West Country in the August Modern Railways that he thinks a mixed fleet of five and nine-car sets is a good idea, but what does he know?
This is hardly a 'mixed-fleet'.
This is a 5-car fleet with a handful of 9-car sets added in as window dressing.
b. Somewhere in the Class 800 thread there is a post by an FGW staff member about loadings on HSTs west of Plymouth after previous posts in the same vein as yours, stating that a five-car should cope just fine in Cornwall most of the time - and the people doing the stock diagramming probably have a fair idea of those services with heavy loadings which will actually need nine or 10 coaches.
But they will never diagram in double sets, they will simply tolerate the overloading of these trains because it is cheaper.
Putting a double train into Cornwall will require additional miles on the likely more lightly loaded return services and is a poor way to use your extra units.
There is a reason that double formation of DMUs were never projected to be a significant use of Voyagers until Operation Princess collapsed.
It is an inefficient way to use vehicles.
c. There's nothing magical about the extra local services on the main line in Devon and Cornwall, their provision is a requirement of the franchise, with the stock needed already identified, as noted above.
Except there are all sorts of problems with the actual provision of this service.
Not to mention that the all shacks sprinter services are achingly slow, even by the low standards of the Cornish Main Line.
d. And don't forget we are talking about Cornwall here, with a population not much more than that of the city of Manchester, scattered over a rather larger area, so unless they are all going to spend all day, every day, riding up and down on trains, they are not going to fill 600-plus seats on your preferred full-length AT300 formations, especially in the depths of winter, same as they don't fill 520-seat low density HSTs right now. Summer weekends are another matter, but the railways have had a few years' practice at revising diagrams to allow for them, so they might just allocate the odd long formation to venture across the Tamar.
Except the extra formations crossing the Tamar have been dying for years.
The number of HSTs assigned to Summer Saturdays has been dropping for years.
Many of the Summer Saturday specials from XC are simply Voyagers (see Newquay).
The modern railway does not do variations to its timetables.
After all, the stock has to be used the entire year, not just in the summer.
This is what the Southern Railway philosophy means when you attempt to penny pinch on stock provision.
It wants to run the same trains all day every day - and they will sized to be always full or overloaded rather than to handle the peak loads.