Sounds to me like you are pushing the material you wrapped around the atty/ carto and the silicone seal when you screw in the cone. Too many wraps maybe? Or, you are wrapping the material too high up on the atty/ carto and the cone can't get a bite on the threads and causing the cone to cross-thread. I've had mine ( a black Vmod) for 2 months and the threads on my cone are still black. Very few leaks! A hot water bath takes care of them. Once the seal is breached by juice it like any other breached seal it will continue to leak until you get the liquid cleaned off and you have two dry surfaces to seal against. As for the soft aluminum of the cones it makes the Vmod kinda "idiot proof". If you had metal of the same hardness both sets of threads could get damaged. Instead of replacing the cone you would have to have a new chassis and a new cone. I for one would rather pay $24.95 for an Aluminum Case & Cone Replacement than $75.00 for a whole new Vmod..........
It's not "my method", it's very soft aluminum. All it takes is a couple times when you can't quite get it on easily, and one of yours will look like that too, because the material is soft enough you don't realize it. And what is this about tight tolerances, as in "precision", vs. zealousness and overcompensating? Why should everything that goes wrong get blamed on the user?
Vmod, 1.5 hybrid, fresh AW IMR and some Kettle Corn from SV...can't get much better!