Hi MasterWolf,
Congratulations on your saber, a very nice model!
Back to the blades though, I think we all need to keep in mind that even though the sabers are highly engineered, there are always going to be variances in fit between parts. Even in top flight engineering like Indycar, Nascar, Formula 1 even NASA, tolerances occur down to 1/1000 of an inch sometimes. Blade whip flexibility probably is at a limit as, to make the blade stiffer, the wall would need to be thicker (reducing colour and brightness).
Hopefully these tolerances can be overcome by the techniques mentioned before and you all can thoroughly enjoy your prized possesions. Sorry I don't have any other suggestions.