I don't think there's an option that would have pleased everyone. Neither Corona or Ensenada are setup to make these. So either they go limited release CS run for three times as much, go with China like the Squier Starcasters, or meet in a middle with Indonesia. I guess Korea would have been a...
I've always done it on a spindle sander for about the 15th fret down, and then a round file in a drill/dremel for the narrower higher frets.
I don't tape off anything really.
I was able to get truss rod covers and pickguards as long as I had a serial number of something recent enough. I usually kept spares too. :shrug:
For hardware and pickups they'd just send a ticket number to give to the vendor (SD, Schaller, EMG, etc.).
That was quite some time ago though.
If you're super picky about neck shapes don't buy ESP/LTD without playing an example of the exact model and series from a similar time frame. There's a good amount of variation across those lines, even on models that have the same "catalog" neck specs.
Don't worry about how they look, worry about how they play.
Typically you'll get them leveled and dressed a number of times before a full refret, so do that when you start having issues that can't be corrected with basic maintenance, and when the frets get too low for your liking get the...
There used to be a guide on TT's site explaining how to use a normal tuner, not sure if it's still there.
The current Strandberg trem is just a Floyd dressed up, knife edges and all. The build feels cheap, but I don't see why they couldn't make them better if they had to.