The brass tube OD is .266 and the "nib" of the pencil is .262 so the nib is just a bit smaller than the tube. So, using the tube method the best that can be done is to round over or chamfer the very end of the pencil blank and hopefully ease the transition. Personally, I like the pencil barrel a little larger than the stock plastic barrel so I do the best I can to make the nib end work for me, look good and feel good.I think I've asked this elsewhere, but you've sorta written the book on these pencils, Don (or at least several chapters of it)... I notice you leave a bump at the nib on yours - is there any way to make a smooth transition, or is that completely precluded by the Pentel hardware? I've only tried making them using the tube method, and I know that doesn't allow for it (although an infinitely thin layer of wood on the tube would come pretty close), but is the tubeless method any better?