Sorry I haven't had time to read all the posts.

But whenever I have any problems like this, I just make the piece much larger.

The bigger the piece, the easier life is. I've already added inches to the sides and temples of my piece, and it has made blending so easy.

Make your piece as big as you need to, don't hold back! It doesn't really cost anything extra as you don't need a fullcap really.

All the best