Blue print the broadhead/washer/insert combo and that should show you if you have any imperfections. It is possible to leave a burr buy bearing down hard on the arrow on the last stroke of the ASD. Blue printing with magic marker on all mating surfaces and re-assembly will show anything like that. Have you tried two washers? How much is the point off and what kind of accuracy are you getting Dan? Maybe you should back off on the tightness of the broadhead? Honestly it does not make any sense. I installed two very long and slender broadheads on my arrows and the alignment is perfect. I am using Razor caps on my compound arrows and Magnus Stingers on my Lazer 2s and they fly just great. Yup you read right Lazers!