Scott, this may be part of the problem.
When you first crack loose a fastener, I like to go about a 1/4 -1/2 turn or so, then stop and go back & forth a bit, to allow anything stuck to the thread to release..then wind out fastener. By hand you can feel what is going on.
Threads should be clean before reassembly, and running a tap down can be helpful. Also if you beadblasted..be really sure you got it out of the thread...and everything else..