I think the rationale behind going for the bigger Savage thread, instead of the normal Tikka thread is to potentially use standard Savage barrels, just like the Ultimatum action. This sounds like a good idea to me.
Now regarding the issue of the thread breaking through because of this, there are two possible reasons that I can think off:
- The designer knew that it will happen, but the benefit of being able to use a standard Savage barrel on the action outweighs the issue of the thread breaking through.
Or…
- The designer did not know that it will happen and just saw the benefit of using a standard Savage barrel. Some might think, with modern CAD technology, how can a designer not see that this will happen and the answer is very simple. Many designers do not model threads, as it can be time consuming and technical drawings does not require a model with detailed thread. All that is required is to model the Major Diameter (for a male thread) and Minor Diameter (for a female thread) and then specify the detailed thread specification on the drawing “1 1/16 – 20”. This can cause an unforeseen scenario of the thread breaking through, only to be realized after metal has been cut.
Will it affect the safety and accuracy of the rifle? In my option, no. The barrel itself is strong enough to contain the pressure in the chamber and the thread breaking through in the middle of the tenon does not affect the bearing length (look at the Accuracy Internal AXMC thread locking method). There is also plenty of thread engagement to prevent the barrel from popping out of the action. Apart from it visually not looking good (which most people will never see), the only slight potential issue I see with it is the risk of a burr forming and seizing the barrel when screwed in or out.
If this is an issue, yet they want to keep the Savage tenon, I would look into cutting a slot to clean up the threads as shown below. This will reduce recoil lug engagement, but it should still be enough.
View attachment 7929902