Badly Screwed?

Pardon the title.. it's late, and I'm sober, but a bit punchy... =^D
Has anyone else had problems fully seating some of the 3mm screws after take apart? In the 300+ successful Mac laptop repairs which involve a total or almost total take-apart (part of my consulting is resurrecting Mac laptops/notebooks by replacing bad screens, HDs, keyboards, etc., and I've been told by several experienced (9+ years or so) Certified Apple Techs that my ju-jitsu's pretty good, good enough to be easily laptop certified in both hardware and software), this has never happened. 00 phillips (brand new), no visible Loctite (only visible on the 3 14mm screws)...
I gently press the center of the 17" MBP bottom case downward as I gently find the thread on the 3mm, after threading just shy of first 'tension', all the other 'easy' screws... I begin to turn with some firmness, straight down, and I get progressive tightness, until.. nothing. WILL NOT turn any further, with maybe a 1.5-2 turns to go before flush. Several 3mm screws will go flush, at least 5-6, every attempt. I've even 'swapped' 3mm screws, to ascertain that some 3mms may thread more easily in different holes, no joy.
The back cover seems to be a kinda monocoque, 'stressed member' of the case; when screwed down, it becomes a tightly stretched piece that appears to add stiffness and rigidity to the entire case. This is why the screw-holes appear to be 'off-center' until I gently press down on the center of the bottom of the case as I start the screws in.
Anyway, back to the saga... tried starting over, placing the back cover on, pressing in gently at the center, and also 4-5" in from the screw-hole I'm threading a 3mm screw into, always careful to line up each hole before 'backing up the screw until 'starting' the thread forward.
I've tried different tightening patterns, progressive, cross-tightening, round-robin tightening, you name it- both 3mm corner screws (latch side) NEVER go flush, and 3 other 3mm screws are close, but not flush like before I started with a 500 GB 7200 rpm HD and 8GB RAM upgrade.
Any advice? I'm uneasy about visiting an Apple Store Genius Bar, an independent Mac service company, or any place I can't 'accompany' my 17" 'business partner', which is a lot of places, I'm quickly learning!
I've not stripped any holes nor Phillips tops yet, but I've put holes two pair of Patagonia pants in the last week (before the Rain Designs laptop desk showed up from Small Dog- yum!), and this is really a vexing problem... I'm embarrassed to admit I'm completely stumped! :^/

Well, Rudy- you're right, and thanks for the heads-up with regard to OWC's upgrade/case-cracking of the 17" unibody video, because I just went with your advice without looking at the video; I could envision the solution you described... worked like a charm, no stripped threads, no loose screws, looks and feels (screw friction when seating-wise), like factory-spec!
I went ahead and bookmarked the OWC video you mentioned, so that I can refer my more adventurous clients who are dead-set on attempting this themselves..
http://eshop.macsales.com/techcenter/index.cfm?page=Video/memory/mbp_uni_17/mbp_uni_17_memh.html
if anyone has a similar issue, thank Rudy!
Again, thanks to all you guys for the constructive, informed input!
Best,
Charlie

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    Little leary about giving them a blank credit card to get service, Badly screwed by Toshiba once.

    I wish there was a apple store that was not a 3 hour drive away.
    To send it to them they hold $20 up front incase they don't receive my phone in 10 days, then it sounds like if they don't agree that the problem is covered under warranty they can bill the card what ever they want. (or is there a cap on this I missed for Canada?)
    If I understand it correctly they ship a refurbished phone immediately though?
    If I do a sync with Itunes is that everything I need to transfer all my info to the new phone. (contacts, emails mainly, pdf books are already on my laptop.
    Thanks

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    On /var/log/system.log I could find the following.
    Feb 22 09:52:29 ogre kernel: jnl: open: journal magic is bad (0xf433f != 0x4a4e4c78)
    Feb 22 09:52:29 ogre kernel: hfs: early jnl init: failed to open/create the journal (retval 0).
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    I tryed to disable the journaling with no success.
    Here is what I get.
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    The selected journaling request does not appear to be valid
    After some googling I foud this :
    --- QUOTE ---
    The more serious problem occurs when the contents of the journal file are corrupted in such a way that the operating system does not proceed to mount the volume. Fortunately, this problem is extremely rare (I have seen three reports of corrupted journal files at the MacFixIt Forums and Apple Discussion Forums since journaling was introduced).
    Starting the journaling process is one of the first things that happens when a volume is recognized by the operating system. There appears to be no way to intervene in single-user mode before the journal file is examined. A message about �bad journal magic� appears. Unfortunately, every tool that can turn off journaling requires that the volume already be mounted.
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    /.journal
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    If the Macintosh cannot boot under Mac OS 9, but the drive has Mac OS 9 drivers installed, the drive can be put into a Macintosh that can boot under Mac OS 9, or an ATA/IDE drive can be put into a suitable FireWire enclosure.
    The possibility that you may need to remove these two journaling files under Mac OS 9 is a good reason for making sure that all volumes you use have Mac OS 9 drivers installed. The drivers must be installed when the drive is formatted.
    --- [END] QUOTE ---
    Well, my disk is part of a RAID 5 matrix.... so the solution proposed does not work.
    Does any one of you has any idea ?
    XServe   Mac OS X (10.3.9)  

    I've seen an article about volumes not mounting and was wondering if this relates to your problem;
    http://discussions.apple.com/thread.jspa?messageID=1239224&#1239224
    The thread doesn't refer to journalling but may be of use?
    HTH

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