Probable answer to the riddle
When you call McDermott you never really know who you're gonna get. Often you'll get a receptionist type who tries to help without wanting to bother anybody else, but today I got a guy who had production experience and knew exactly what I was describing to him. It seems that in spite of trying to use the same hardware supplier when ordering pins, sometimes the supplier itself has a batch of pins that may have a very slight variance from the previous batch. So, it can be a bit of a crapshoot, depending on when a particular cue was made. This would explain why a butt and shaft usually go together smoothly when shipped together-they hand fit them before shipping. But introduce a shaft made at a different time and maybe, maybe not.
He says if you encounter such a problem the solution is easy: just run a 3/8x10 tap into the shaft threads. He usually backs the tap out halfway to clear the sawdust. He did say that 3/8x10 taps can sometimes be hard to find. When I asked if they used standard or modified he said he had never heard of modified so he supposed standard.
He further said they had let a batch of mid extensions get out a while back that were slightly out of spec, so that would explain my problems there.
Could anyone confirm that recent production McD 3/8x10 pins are indeed standard and not modified? Mine are all at my other house with my table and I won't see them until the weekend.
I'm hopeful this works. It makes sense.