[PlaneEngnr]

I purchased a shotgun with a hole where the bead should be, easy enough to fix. Drilled out, 6-48 tap, now its standard remington size, got a giant orange fiber bead thing from local place. Screw it in, comes out a little crooked, just stone some off the bottom face till it lines up, but it protrudes in the barrel maybe a thread and a half. I'm just planning on stone/filing it down flush, as in perpendicular to the threads, and reinstalling it.

My question is wether this is safe or not, their won't be any protrusion in the barrel but the sides won't be totaly flush, if not how can I get it to fit correctly.

[kirbythegunsmith]

I have seen instances of less-than-stellar accuracy in the bead bodies and shanks, and sometimes the threads are not nearly flush with the flat underside. In that instance, you might understand the "lean" that could develop when the thread becomes shallower to the point of disappearing.
You may be able to cut into the shank on the side where there are not sufficient depth of thread to make a small undercut to remove that part of a leaning condition.
It is slightly possible to tap a hole that already exists (unintentionally) at an angle, and that situation is more interesting to remedy.
You must do the best you can to make the protruding shank as unobtrusive and blended, but try to avoid excess scratches out of the bead zone, if for no other reason than aesthetics.

Here is an example of "before, during, and after"

kirbythegunsmith@hotmail.com

[porterdog]

I installed a tritium bead on my 870 and wound up in the same place as you; protrusion, and the bead wasn't aligned with the barrel.

I marked on the barrel where I wanted the bead to be and taped around the marks. The put a thin smear of JBweld over that. Threaded the bead in to where it ought to be, waited 10 for the JB to thicken a bit, stripped the tape, waited overnight, used an abrasive wheel to take the protruding bit off.

Was careful; worked great. The tritium capsule can be replaced without bead removal.