(SolidWorks 2012 SP 5.0, Premium (-ish, really Basic plus, calls itself Premium, but without all the Premium features)

Having trouble inserting male NPT Cosmetic Threads into parts.  We model our parts with NPT at the Major Max Diameter, including the taper, for a visual cue to the NPT.  We like to show the cosmetic threads, only for the dotted line it presents in drawings, as another visual cue.  This allows us to make parts both from paper drawings, and for some machines, by importing the solid model into CNC software with minimal editing by the CNC machinist (he can rough the part out with a small offset from the model, and then thread on the next operation; they are essentially screw-threading these on a CNC lathe, not using thread dies).

The SW part itself is created by extruding the stock hex size, and then doing a cut revolve of the outside profile.  We've found this to be the most editable, and closest to production methods.

I've been working around this error for over a year, but finally want to check and see if anyone knows how to fix this.  This time, we have multiple views of the same part on the drawing, and it's a pain to fake the cosmetic threads with the antiquated sketching capabilities SW has on drawings themselves, and then having to draw the same feature in each view, which presents a maintenance headache.  I keep threatening to get out the old T-square and Rapidograph pens, I could get this done in a fraction of the time.

The error itself is really puzzling.  SolidWorks is auto filling the diameter value, yet still says the value is incorrect.  This is 1 inch NPT. The dia of the edge I select is 1.256809in (the small end of the NPT, after adding a chamfer). Note that the Cosmetic Thread tool says I can only have a max dia of 0.33, which makes no sense.

I only selected the Straight Pipe Tapped Threads as a stand in for what I really want, which isn't available (NPT).  I've tried every available Type, and nothing will allow me to insert a cosmetic thread large enough to be believable.  All of the choices have glitchy response to different Diameters I enter (if the option allows it), where larger values produce smaller thread size, up to a point, then they jump to a smaller size.

I don't really expect to actually be able to solve this, just want to know if it got updated in 2013, and if not, maybe will be addressed in future updates or service packs.

Thanks for anything,

Chris