Hey Bill...
Tell me exactly what problems you are having....
3-4 layers on each side should be plenty enough to create a buffer between the sheath and knife....
If you are having scratching problems still,,then it more then likely could be your process...
Make sure the knife does not twist when it goes in the mold..Some knives like to turn slightly,causing a concave press on one side..
This happens sometimes and is hard to control on some knives...
Make sure the press you are using is giving you accruate even downward pressure....
Another thing you want to keep in check is cleanliness..The grinding process will introduce grit inside your sheath,,if this is not controlled ,,you will have BIG problems with scratching...
I have a special way of controlling this grit problem and wash the sheath under high pressure Anytime sandpaper is used on the sheath.
If you are getting actual scratching and not just Scuffs or Buffing,,then look into the cleanliness of your process..
If it's scuffing and buffing,,you've got other problems...
The taping of the blade should be neat trimmed and seamless..
Hope that helps...
Feel free to e-mail me with specifics.
ttyle
Eric...