IIRC, there are only a handful of platforms that are too short for 6 cars. Warminster, Trowbridge P1, Bradford-on-Avon (I think?) and Filton can all handle 5 max, but I could myself be mistaken. I don't think extending any of those would present any major challenges, with the possible exception of Filton which might require realignment of tracks to keep the island wide enough. SDO would probably be an acceptable, if imperfect, solution.
Fixed-formation 6 car is probably not a sensible option though, massive overkill on some of the early and late services. Pairs of gangwayed 3 car units would be much more sensible, as long as GWR don't get in the habit of sending them out solo on Saturday mornings...
Although rare, occasionally the line does see two 3car units coupled together (I have personally observed it), instead of a 3car + 2car
Part of the problem is the volume of short journeys means there is big churn at places like Bath, so units with just 2 double doors aren’t that suitable in long 23m vehicles. (A 115-120m train only has 10 pairs of doors instead of 12)
But the biggest problem short term is the random mix of train lengths, with various services reduced to single 3car sets often at short notice. So clearly there aren’t enough sets currently allocated which leads to so many trains suffering overcrowding on part of their journey.
I do wonder if a gangwayed power car (bit like those on the prototype class 210 DEMUs) are the answer, if there are surplus newish EMUs around (which there are) with a new power car added to a nearly new surplus EMU. But really it needs a dual electric bi-mode (not a 125mph version), nearer 90mph on diesel or 100-110mph on electric configured to be suitable for mix of outer suburban and 3-4 hour journeys.
I don’t actually know if 5 car set could provide the capacity required, and 6car operation needs a few short (but easy) platform extensions. Ideally there would be mix of 4car and 2car (but fully gangwayed), so that don’t need to run excessive long trains at quiet times (and before anyone comments, mixing 2car and 3car is already done today, so not more difficult to have mixed fleet going forward). Although I don’t really trust GWR to couple up sets for busy journeys so might be safer to just order 5 or 6 car units
But I also think the 165 & 166 turbos should be refurbished with seats from withdrawn trains, they are not life expired, but they are not really suitable for services of 3-4 hours (or 5+ hours in case of some services from Great Malvern to south coast) and should be redeployed to other shorter services.
I think the synergy of replacing old diesel stock elsewhere justifies electrifying Bristol-Bath (actually Filton-Bristol-Bathampton which has 3+ services each way per hour), then onto Chippenham and Westbury. However short term adding Westbury-Salisbury-Redbridge and Salisbury- Basingstoke-Reading West is harder to justify. If just this part of the route can be electrified then could probably reduce the size of the diesels or have an 80mph diesel top speed, but keep the 100-110mph electric top speed.