Don I agree with your statement about bent mandrels. Like I have mentioned here I still use the same one I have been for 12 years and still works fine. I turn one blank at a time because if you break it down that is all you can do even if you mount both on the mandrel. Yes it takes an extra minute to change blanks but again I am repeating myself, most problems arise from human error and the rush they are always in. Most of the time it is not the tools but the operators of those tools that are the cause of problems. I finish with BTC but always turn with bushings.
You mention OOR and there are tricks for many problems that arise but for the OOR there are a few factors. Yes bushings can be a problem, not squaring the ends is another, bent mandrel another and I am sure there is more. But a little trick that hardly gets mentioned here is to rotate the blank ever so slightly as you turn the blank down close to finished size. This will spread the error out over the entire blank more evenly.