I need to make a small repair on my Franken Mill

[Sunset Machine]

The pin hole would cause me more concern than the threads. I'd have used the sequence of cross drilling first, see if it fits the knob, cutoff, then thread. Matters not a lot in this case, but little things like that can scrap parts. Much better to cutoff a misplaced hole than have to scrap the threading too.

As to stickout, I use an actual rule of thumb. That is, I push the end of the workpiece with my thumb. If it moves it's no good, needs better support.