It's not an engineering reason. Back in the 70's, the 5 thread DIN was the norm and used regularly at 4500psi. I even have a Poseidon regulator with the 5 thread DIN, rated for 4500psi, that won't even work with a "300 bar" 7 thread DIN. The 7 thread DIN came into use in the SCUBA industry later to prevent the few DIN regulators that were unable to handle pressures over 3500psi from being connected to 300 bar tanks. It is not a DOT requirement. The 7 thread DIN is no stronger than the 5 thread DIN as far as pressure handling capability, in fact it is actually weaker on impact resistance. Thermo's catalogue shows service pressure based on installed burst disk but the actual service pressure of the valves themselves is the same for all versions.
You may have asked Northeast SCUBA the wrong question. What you need to put either "300 bar" DIN, "232 bar" DIN or Yoke regulators on your tank is a Thermo 8082RH-5250 Modular Valve (7/8" inlet thread) and a Thermo 9020RH "H Connector Attachment". And a Plug for the unused port. These parts will easily handle 3500psi and more.
As far as removing some threads from a "300 bar" DIN valve, you will loose the chrome and also the body probably doesn't have the dimple for the yoke screw.
You may also be able to find a machinist to re-thread a K valve to 7/8"-14 UNF thread and change the burst disk. That is legal.
But.....as others have said, the better solution is to convert the regulators to DIN. You can put a DIN to Yoke converter on the regulators in the field without tools if needed.
You may have asked Northeast SCUBA the wrong question. What you need to put either "300 bar" DIN, "232 bar" DIN or Yoke regulators on your tank is a Thermo 8082RH-5250 Modular Valve (7/8" inlet thread) and a Thermo 9020RH "H Connector Attachment". And a Plug for the unused port. These parts will easily handle 3500psi and more.
As far as removing some threads from a "300 bar" DIN valve, you will loose the chrome and also the body probably doesn't have the dimple for the yoke screw.
You may also be able to find a machinist to re-thread a K valve to 7/8"-14 UNF thread and change the burst disk. That is legal.
But.....as others have said, the better solution is to convert the regulators to DIN. You can put a DIN to Yoke converter on the regulators in the field without tools if needed.