My endo had trouble with the cannula too. She ended up giving my the cortosyn via IM (intramuscular). I was freaking out, since I did not know whether this could upset the results of the stim test. I later did a search on the web and found out that the IM is a perfectly acceptable method of cortosyn administation ----at least according to the standard med literature I read ---others here may know more from experience.
At the least, it seems your drs should have known this

and been able to complete your test.
I can't answer your other concerns, but my impression is that drs of this sort are not interested in scientific validity of tests such as this, since they seem to feel often, that such tests are unneccesary and second to compaining patients who have a lot of somatic complaints and blame their endocrine function.
Was there anything specific which originally prompted your dr to order the stim test?
My test was less than valid, since the lab "forgot" to draw my ACTH in the morning when my AM cortisol was drawn. It was just ridiculous. The dr is like "oh, well, we don't really need that".
