Excellent post Mortmeister, it fills a lot of holes.
With regard to tightening the Nut, as I have stated previously on this thread, I was taught 'max 1.5 threads showing above the nut,' but critically to ensure that there was freedom of movement of the Drogue Withdrawal Line in the Scissor Shackle. As for exactly how that was stipulated in the 1J I don't recall, but we were certainly aware of over tightening said bolt at Chivenor back in the early 90s.
So MoD was in the know in the early 90s. Fits with the MB statement, that they claim they couldn't find, and the Tornado incident.
For me, a major factor in this incident was leaving the seat on the actuator down limit because the same pilot generally flew the same aircraft. This was against the procedure for af, bf and tr and would seriously restrict the view of the Seat Pan Pin for anyone entering the cockpit. Had the Actuator failed (as they sometimes do) it makes it a much more difficult task to remove the seat for rectification.
Agreed. Although I can not understand why no one thought of pressing down on the base of the firing handle, to make sure it was seated correctly, before inserting the pin.
In 6 years on a TWU on a Sqn of around 20 aircraft, student pilots, fast turnarounds, high pressure, I never saw a Seat Pan Firing Handle in this condition, although I was aware that it could exist.
Probably becaause people were properly trained, applied common sense, and treated an ejection seat with respect.
DV