Problem with liners...

Are you flattening the liners as well as the scales and tang? I know at least with fibre liners they aren't always perfectly flat.
I found it to be helpful to glue the liners to the scales, then flatten the liners once they are on the scales. The lumps on them can be noticable on some sheets if you try sanding flat.
That is the method I use. I always glue my liners to scales first then flatten.
 
If tang and scale/liner combo are absolutely flat and you've roughed and cleaned the surfaces adequately it would seem the source would be starved joint or over heating.
 
Just to make sure they are flat, glue to scale and flatten,then hold the on the tang and look at a bright light, if any light come through they are not flat, also use very little pressure when holding to the tang. You can over power a slight amount of bow with pressure but will make the joint fail when glued.
 
I use epoxy to glue everything up, but I color the epoxy the same color as the liner so that if there is any slight gapping the epoxy will fill it and it will be the same color. Hope this helps
 
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