The Sphere Builders were able to accelerate their transformation of space only after the Spheres had been doing their work for thousands of years. They won't be able to recreate the Expanse in the 400 they have. If they could, they'd have done so immediately after placing the spheres, long before their rivals achieved spaceflight.
The sphere builders are not the only faction with time/whatever tech, that can compete on that level in the 22rd century and before. They may have been trying to hide - which was why the spheres were working so much slower than their normal capacity.
If the only reason the sphere builders didn't create altered space fast was because, until recently (S3), they couldn't, then in S3 they would have started the accelerated creation of altered space
(they didn't) - no federation in the 22rd century to stop them.
Also - between the 22rd and 24th centuries are 400 years - time enough to improve their technology, making the speed of creation of altered space even faster.
About 'Procyon 5 doesn't exist anymore' - it's an assumption with HUGE problems, which you omitted to address:
"It doesn't fit what Daniels said/the scenarists' intent (as displayed in the relevant sequences, etc).
It leaves you either willfully ignoring large parts of the sequences, their tone, etc ('momentous event in history', etc) or with FAR larger inconsistencies (the federation not existing to fight if Archer failed; Daniels not caring about massive alterations to the 26th century, etc)."