There has to be a better way to inspect timed threads than what we are using. We have a set of masters that when screwed together a matching flat was machined on each. The masters were then used to make working gages using the same method. The driver was standardized at 7 in-lbs and then at 30 in-lbs. The thread plug has a hex in it. The size is small of course 1/4-32. There are only 1.5 threads of engagement on the parts (more on the gages).
We can't seem to get better than ± 2° out of the working gages (40% of production tolerance determined via GR&R). To make maters worse now, the higher pressure is wearing the masters out. Masters that were in print at the start of the GR&R are now 2 degrees out of tolerance plus the hex is rounding out.
I'm afraid to go with carbide with the higher pressure since I think it will just break the threads or head or strip the parts.
Now the question, is there a commercial method out there for this? I can't imagine that we are the only company with this issue (watch makers come to mind).
Most of the seraches I have done only give me discussion thead tools or standard inspection methods.
We can't seem to get better than ± 2° out of the working gages (40% of production tolerance determined via GR&R). To make maters worse now, the higher pressure is wearing the masters out. Masters that were in print at the start of the GR&R are now 2 degrees out of tolerance plus the hex is rounding out.

I'm afraid to go with carbide with the higher pressure since I think it will just break the threads or head or strip the parts.
Now the question, is there a commercial method out there for this? I can't imagine that we are the only company with this issue (watch makers come to mind).
Most of the seraches I have done only give me discussion thead tools or standard inspection methods.