I generally buy my fret wire from LMI, so it comes coiled, and almost always a smaller radius than the fretboard, so I usually don't pre-radius them any more.
I wasn't aware that glue should be used though. One was a maple neck, so I will try that. Any particular glue? Also, glue overrun is rather unattractive, so is there any way to prevent this overrun, or clean it up efficiently afterward?
Assuming the fret tang is too small for the fret slot, what could I do to widen the tang?
I will try using my smaller 7.25" caul first, to get the ends more securely settled, before pushing the center down with the proper 9.5" caul.
Thanks again for all your help everyone.