Hey Tito...
"I've been experimenting with masking tape, but I'm not quite satisfied - this method tends to make it difficult to get a superb fit."
That all depends on where you take your fit from..
Fitting a knife can be tedious work, each knife is different and takes the lock from different places...
By the sounds of what you are saying you are taking the lock from the lower guard or ricasso area of the knife..
A Skeleton knife is obviously more difficult to get a lock on, but a knife with scales, depending on how they are shaped,, you can grab a lock off of the handles and or lower guard...
Can you post a picture of the knife?
If you are taking the lock off the Ricasso area, when you peel the tape,, there should be a slight rattle...
That rattle is easy to get rid of depending on how the knife is made...
If you guard and shoulders of your plunge line are square and sharp, your going to have "skating" as the knife comes out it drags through the sheath.. If rounded,, they glide through the sheath..
Another little trick is to use some Snap brand silicone, give your finger a shot, and wipe it inside the mouth..
If the knife is too skinny either dap some on a Q-tip or dap it even on the knife,, then re-insert...
Silicone in the sheath is like Nigh and Day,, however,, overdoing it can be a pain in the ass and make a tight sheath too loose to carry inverted,, the knife can slip right out...
The amount of tape (on the plus side) you put on the blade, should have little effect on the fit of the sheath,,as you shouldn't be taking the fit from the blade..
If you've got lateral movement at the tip,, give it a few seconds of heat and push a dimple in the back,, right at the tip..
" My problems only started once I was able to bead blast - the least amount of grit inside the sheath, and the scratch shows up real well."
Are they scratches or Buff marks ??
Clean the sheath out Very well,, there shouldn't be Any grit inside the sheath at all...
" I'm fairly certain the grit is from the grinding belt,"
Do you set your eyelets Before grinding ??
ttyle
Eric
O/ST