Several times when this subject comes up, folks ask "If it works for a spark plug in my engine, why won't it work for a nipple in my rifle?"
To try to answer this question, I've made a scale drawing showing a spark plug installation and a nipple installation, both using helical thread inserts.
The spark plug was drawn at full scale and the nipple was drawn at twice size so it would be easier to see.
In a typical spark plug installation, there is either a gasket or a cone area of the spark plug that seals directly against the cylinder head. This prevents any escape of the high pressure gas from the cylinder.
Even with a helical thread insert installed, this gasket or coned area will seal the assembly because the gasket or cone is larger than the outside diameter of the thread insert.
In the case of the nipple, which is a standard #11 rifle sized part you will notice that it also seals directly against the breech plug, just like the spark plug.
I derived the dimensions by direct measurement of one out of my Franklin Co rifle.
The difference between the spark plug installation is the lack of a large gasket.
In the case of the nipple, the remaining sealing area is only about .005 (five thousanths of an inch).
As the nipple and insert were drawn at nominal size this remaining surface interface may not reflect the real world.
If the thread insert chamfer at the mouth of the hole uses its tolerance and goes to the high side, the .005 wide sealing area will disappear and there will be nothing to actually seal the high pressure gasses from leaking past the thread inserts threads.
Assuming the leakage will be minimal compared with the leakage around the fired cap, one is still left with the fact that the screw thread insert is not water tight and cleaning fluids and fouling can enter into the joint between the insert and the breech block.
Of course, if GM uses a suitable sealing compound between the thread inserts threads and the breech block this fouling and fluid entrapment issue would not be a problem.
By the way, I drew the shortest helical thread insert that I know of. If GM used the "1T" length insert, it would extend down below the bottom of the nipple. I believe this is the cause of the flame channel being blocked off in some installations.
zonie