Hi Trapper
For me you have hit the nail right on the head, the depth of the thread issue, if I want to have say a 13mm internal tube diameter , I understand that following on from the tapping procedure I'm still left with a 13 mm tube with a thread cut in it, however do I then have to have a tube to go in this that is 12.75mm plus the depth of the thread so that they mate properly or am I missing something obvious. If this is the case then I understand it.
So in practice drill and tap the tubes first because they are dictated by the drill size and then turn the inserts to fit is that it? or am I really being a Richard Cranium here?

Could some of you better informed engineering trained turners suggest a tap and die set that would suit my needs, I'm going to stick with a single twist to maintain the alignment and will only be turning either acrylic or wood.