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Mike,
I've changed zincs on the old 3208 Cat's and have had the same problem. First off, I don't use old plugs but use new plugs with new zincs (no corossion or dirt/salt buildup). Then I would snug the zinc to the plug by holding the zink with a pliers and a wrench on the plug. Just a little, don't overtighten or mess up the threads on the zinc. Add in the silicone that Airship mentioned and change regularly and that should help fix the problem. Next time you have the zincs out, look in the hole with a flashlight and make sure there are no old zincs or anything else inside to bind up against.
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