Mike,
As you're probably figuring out, all front sections are not the same size, without knowing what section you are using I can't offer much help with what you are experiencing. I will offer some things to think about however...
When I use a Berea front section I drill the blank with an "R" drill bit then tap with a 10 x 1mm tap. This has worked fine on over three dozen pens now. Before saying anything further, I would appreciate it if folks wouldn't post just to correct me by quoating from a machinist threading manual. The threads used on the front sections we encounter are NOT standard threads, at least none of the sections I have used. The Berea sections are not 10 x 1mm BUT they are close enough to work.
The front sections that come with the Craft Supply kits as well as the smaller Schmidt sections are too small for a 10 x 1mm tap and will fall right through the hole, I suspect this may be what you are experiencing.
If you want to use the 10 x 1mm tap, I would suggest visiting Arizona Sillhouette and having a look at his Berea nibs #BHW-703, BHW-704, BHW-705.
For the Craft Supply, Schmidt and sections sold by several other vendors you will need other taps. It's good to have a nice selection of taps, that is why I visited Victor tap and die.
Another thing, if you look at a front section where the threads stop, there is usually a small shoulder, some are squared off, some have a slight radius. In either case, once you tap the pen body you will need to clean out the inside where the threads start so the shoulder will fit inside the body. THis will be very obvious when you try to thread a section into your pen and it won't thread all the way in.
Hope this helps some.