I never had an issue getting the battery cap back on. Once you push the battery down enough to seat it, the caps have always went right on for me. If you don’t seat the battery, you’ll have issues.
I only had trouble with the first one that I bought, due to it being so thin and having so few threads on it. The replacement cap is plenty thick and hasn't been a problem at all. I replaced my battery yesterday. I have 2 others that have been fine too.
I think the problem might have been with the earliest ones they produced, and they corrected the issue. As you said, you gotta seat the battery first. The Burris is a good sight, but I sure wish I could still see well enough to get by without it.
