Many times I have had stuff come in that someone else has worked on. Muzzle devise screws on, but is loose like AeroE said. Then I try to put another type of muzzle devise on and NO GO! At that point I would check threads with a thread checker (go figure) and see if the threads were done correctly. As for length of bbl hurting accuracy, unless you are shooting high power/ long range matches, and hand loading, it should not make enough difference in impact that you can not adjust for. When I do that job, I get the threads down to the point that the muzzle devise will barely thread onto the bbl (1/2-3/4 of a turn) then I step down to only making .001-.002" cuts. Sometimes all it takes is running the thread again without adjusting. I get my threads tight and smooth right to the end of thread. It's not rocket science, but it does take patience and attention to detail.