Hey Rippin,
Nice set of photos!! What camera and lens are you using?
On photo #2, it looks as though you could cut a bit of the plastic (half?) away on the side nearest the boss. That would buy you a little bit of stud. Then you could countersink that same side allowing the boss to sit further into the hole giving even a bit more stud. Or, just use a larger countersunk hole to start. Of course, this modification could mean the bottle cage plastic may damage the boss and paint unless you matched the countersink angle to the boss angle.
I have a similar problem on my old Carbon Frames and cheapo Performance cages. No cutting required, but I had too little threaded stud showing for properly securing the nuts. For my fix, I inverted the nylock nut on one stud and used a thin "jam" nut with blue locktite on the other. It was an experiment to see which loosened and failed first. Well, it's been YEARS now and both are still secure.
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Skuke
95 Carbonframes Tetra Pro
92 Bridgestone MB-1
90 Moser 51.151
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