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Smallest muzzle diameter for 3/4 threads?

You will be fine with 3/4-24 threads. I use 3/4-24 whenever I can.
Cut the threads to closely fit the device you buy without being too tight, just snug. Use Rockset as mentioned above, and don't ever over tighten any muzzle device, as you can deform the barrel at the most critical area.
 
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