am using the TK53&54 bodies with the build in drumstick. will be running a 1/4 inch treaded rod into the bone of thelower leg. wanting to know how mush to leave between the form drumstick & the leg after this is build up.
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And I know plenty of people who use this, but it's still not a good idea. Thread stock is stressed metal already and bending it can weaken it very quickly allowing it to snap off. Best bet is to use 1/4 in cold rolled steel and buy a corresponding die to thread the ends. Then you can cut it after you get it ready to mount on the diorama and cut your own threads only in the end where the rod will retain all of it's original strength.
i shove the little peice of wire into the form and then run a couple of drywall screws against the bone on each side to hold it in place while i bondo.
the bends in the rod will not be major enough to worry about unless you are going for a really wild leg pose. i use the same method you do and the results are a very solid bird.