Hi Will,
I appreciate the thought put into your post. I used a device like the sen (didn't know what it was called) in a prior life. A tool and die maker was a fellow skier and he showed me a device he used to sharpen skis. At the time, I found it took too much material but for the application described, I clearly see the value.
I'm doing mock ups in wood with different handle wrap configs. Thicker was more comfortable but throws off the lines (imo). I agree with you that for extended use, this may not be the best design. To that end I was shooting for a unitype handle that will allow for tsukamaki or cord wrap with varying underlayment thicknesses or more ergo shaped scales. This may be one of those trade-off/compromise areas but I will go as thick as possible. That concern came up more than once.
If I can achieve all other design objectives and not be able to baton/split a 2" dried out, foot long piece of tree limb, I may just have to get up off my lazy rump and go get the darn axe. I can live with that and appreciate being told up front the design won't support the app. As Dirty Harry once said: "A man's got to know his limitations."