cayugad
I am really sorry about your experiance with the Knight and I really do not understand how it would happen if the seal was achieved and not broken until you took the plug out. One of the things that I have done was to check the mating surfaces of the breech plug to the barrel flange by blackening the lip on the BP screwing it into the barrel then take it out ckeck the blackening - it should show contact all the way around the plug.
Often installing the plug will feel like you are cross-threading, when that happens I polish the BP plug threads and and the threads in the barrel with JB's - all thread cutting machines leave very sharp threads and burrs. After polishing you normally get a betterand smoother fit.
The thickness of the tape is important issue to solve - the Remingtons all use Pink tape. The A&H uses pink tape but you must turn the plug in your fingers and work the tape down into the threads before putting it in the barrel. The Omega requires one wrap of white tape and the threads of the BP and the barrel must be clean. The White uses pink and does not require any pressure on the tape before inserting it. I have never found a gun I could use the yellow tape on yet.
It sounds somewhat complicated, but I firmly believe in stopping blowback before it gets to the threads of the BP. After reading the documentation on Toby's accident whether he caused it on purpose or not... Gas cutting is/can be a problem. Most of the gas cutting from blowback you and I will never see. Doc White is aware of the problem and hardens his BP's to such a Rockwell number just to insure cutting is held to a minumum.
And when you get back to the basic premise each ML is different I guess you need to do what works for you.
Apparently we have both solved the BP problem each of us doing our own thing, I just have a hard time with the concept of loosing on purpose the breech plug - I know a lot of people do it but my mechanical background just will not let me do it...