Gene, We all have our own methods, and I've used most described here at one time or another Myself, so any of them can have the same results, just depends on what works best for the individual. I have cut them with the tip on also, and had success. The method I use now is simular to what sheldon mentioned. It takes some time to to get the hang of It, but I really like the cut of the razor on the tip, so I basically turn the ferrule first, face it off, apply the tip, and then use the razor method to trim the tip. After that 400 grit and up works fine for polishing. I do not have issues with tapering the ends/tip, but then again, I am very aware of that issue, and apply even pressure through the ferrule not just on the tip, so It's never a problem. that's the nice thing about the razor method. It does'nt require you to sand on the tip as much to even It out or polish. It all starts with a good cut on the ferrule in the first place though.
If You are not familiar with the razor method, then I highly recomend you seeing it done before ever attempting it. It can be very dangerous, and not something you want to guess at on how to do. You really need to see it in action first.
When I face, and tip, I chuck It up closer in the jaws, then when using the razor method I rechuck to give me room to work. It's rare that I do a tip without rechucking atleast once. This does not include dialing the work piece in.
Sounds like Your doing pretty good to me By what you said, If most are coming out good, then your probably just running into a tuff one every once in a while. I am picky when It comes to that area of a shaft, I only feel good when you can run your finger through It, and not feel anything where the ferrule meets the shaft or where the tip does. Anything less I'm not happy with, but sometimes they can still be alittle stubborn, and ocasionally despite My best efforts, I'm not always completely satisfied.
On the sanding, I sand dry with wet/dry paper, but you could wetsand I suppose. If It were Me, I would try to limit It to the ferrule though, and I might be concerned with any water soaking in the tip too deeply If It was already on the ferrule that is. Also even when I dry sand the ferrule, and the tip is on, I like to burmish the tip before sanding or seal It with ca. Some tips would be fine, but some will stain with the dust from the ferrule, and you can see it in the tip after the final burmishing, So not only do you have to worry about staining the ferrule with the tip, but the same goes for the opposite if your really picky
Greg
