I still have that problem from time to time, but it got a lot better when I prepared the bushings with just a light touch of Minwax Paste Wax before starting the CA finish.
Also, when I loosen the mandrel and find the barrels stuck to the bushings, I tighten it up again and use the tip of a skew chisel to touch the dividing line (slightly towards the bushing so I don't mess the finish on the pen.)
I too have this problem and find that a little paste wax on the end the pen works most of the time. Also, this problem is worse the thicker the ca finish is built up. Thinner total coats make this problem less pronounced. I have scored the line as well where the pen and bushing ,meet but it isn't a perfect solution.
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