Strange several people have found inconsistencies in sizes and I take apart and anodize a ton of these and have never had a problem. Curious were these knives bought brand new? If not are you sure the parts are not parts from the secondary market? I know for a fact at least one person who posted on here 100% has aftermarket screws.
I have found in the past when we used to do anodizing for people who would send their knives in to be anodized that we would have some issues. Most of the time it was either secondary market parts or they had taken them apart with some cheap torx bits. I highly highly recommend Wiha if you are going to mess around with knives. Their bits will save you a lot of headaches, strip screws and weird sizes.