I can vouch for the IWB carry, but I might have a slight advantage over most...There is a Kel-Tec shaped depression over my right hip from years of carrying it...and a good callous built up as well...I don't notice my VG when I carry it over my hip......
On another note, I have never had any problems with wear on my jeans from pocket clips, save for the clip on the back of tape measures. From what I observed, the pape measure's wera was from the lip of the clip draggin as it is being clipped on. a little bending prevented further wear. Another possibility is that the knive moves side to side from body movement. If this is the case, you should put on a couple of pounds so your waist will migrate down a few inches, and hopefully you will be able to position your knife pocket in a place where it does not move as much from daily activities.
A third possibility, mentioned earlier, and I have to remention it because of the possibility of using a Dremel, is to smooth the clip edges. My suggestion is to remove the clip, and use the "grey eraser" poloshing wheel to deburr and round the edges of the clip's underside.
YeK
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God is dead. -Nietzsche
Nietzsche is dead. -God
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