Let me open this thread response by saying "Please don't leave us". I can't tell you how nice it is to have another member join us who understands the archery and arrow technology as well as you do. Like you, I've written numerous articles about how to properly clean shafts, or numerous other facets of building arrows, tuning shafts and set up and tuning of bows.
You may well be the third Musketeer in our trio on this forum. Super 91 is also very experienced. Much of what is being written and discussed here has many variables, so every bit of information is correct, it just depends on the application it's used in.
A couple of quick points on your last response. We would typically assume that a major shaft producer would be using good shaft cutting equipment, so I've sort of discounted that as a problem. That said, I agree with thye possibility and have seen shafts get out of balance when people try to use hand saws and cheap cit off wheels to cut there own shafts.
As I stated previously, these shafts are very unique. The straightness tolerances for these particular shafts as posted by PSE are as follows:
arrows takes carbon arrow design to a new level with radial X Weave technology. Incredible straightness of +- .001 the Carbon Force Pro is the straightness arrow PSE offers. A patented computer process wraps individual carbon fibers to create a weave pattern to make the arrow stronger, straighter and faster than conventional carbon arrows. Shafts are full length with inserts loose and nocks installed. Arrows are fletched with either 3" Duravanes or Blazer vanes.
The arrows are fletched in a 4 fletch configuration, but not 90 degrees per vane as usual. They use a 60 x 120 degree configuration placing two vanes close together on either side of the arrow shaft to achieve optimal flight performance.
The method you described of tuning broadheads to arrow shafts is the standard method we've used for many years. That's because when nocks are uniformly indexed to the stiff part of an arrow spine, we want the broadheads to align the same way to each arrow spine to maintain identical flight characteristics. This achieves consistent flight performance from arrow to arrow.
This has not turned out to be possible with these new fiber filament weave arrows because the spines do not align in the same manner as normal so the nocks are not indexed to the spine at all. Also the shaft compression from arrow to arrow varies considerably. This means the flight characteristics are different from arrow to arrow.
All arrows or shafts are pre-cut to 26.5 inches, so cutting down the shafts to replace inserts has not been possible. When wobble is detected in a shaft by spinning them, we typically remove the insert, discard it and replace with a new one. Then re-spin and rebalance the shaft.
Some TAC owners have been having more success by sorting their TAC15 arrows into groups based on the performance of each shaft at a long distance. Also rotating each broadhead to achieve centering at 70 to 100 yards has worked. We are still searching for ways to identify a fool proof set of tuning steps that will permit all arrows in a given dozen to perform the same for tighter groups.