Hey all. Thanks for the follow up replies. I am not sure what I was doing wrong before, but I have had better results as of late. This is probably primarily due to figuring out a few tricks to help salvage the blanks even when I have a problem, such as not cutting them to size until after drilling the holes. I have also had better luck by simply slowing down a bit and using more glue. Finally, I have been sticking to the gouge and not using my skew, as I think the skew was catching the blank and causing alot of the tearout issues. I still get a bit nervous until I get the end of the blank turned down to the bushings, but overall I am having better luck.
On another note, I finally got the CA method of finishing blanks down pretty well. Though it does leave the pen with a more plastic feel to it, I really like the shiny finish and the enhanced durability it offers. Only problem is now the pens I finished before learning that method look dull and boring...
One other thing, I had a blank that chipped after installing the parts on the end cap of a Majestic Junior (poor glue job). Any idea how I can get those off so that I can salvage the kit? I could probably just compress the tube with vice grips to get it off, and if nothing else that's what I will do. I would ideally like to not have to order new tubes though so another option would be great.