I've had more than my share of blanks chunk right off the tube. Usually it's the oily woods & I don't think I got the inside of the blank wiped out good enough before gluing. I use a Q-tip dipped in odorless mineral spirits to swab it out. I try for 100% glue coverage by working the tube in & out while rotating. I do this from each end to ensure the best coverage.
The irregular grain in Burls will also splinter off the tube if light cuts aren't taken as you are well aware.
Rather than making the blank the same size as the bushings over the whole length I've also found it best to leave it oversized thru the middle & that has lowered the splintering chances for me.
It may not be fair for me to say how long I'm at the lathe for each pen since that's all I make. A simple crow call takes me 2hrs easily.
My CA finish always starts with 4-5 coats of the thin CA for penetration. There's usually no need to sand any of these coats. Then I go to the medium for my top coats.
Your perfectionist mentality is what makes you & all the other call makers on here the very best there is. Don't blame things on that or ever let that go!!
And I stand behind my comment earlier,,, Purdy darn nice pens Clint!!