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You say the depth is .255 how thick is the material your using cause depending on thickness of material will determine finale thickness of grip unless you lower it.

Here is a pair of 1911 grip straight from scan so you can play with it as you like.
A couple of things to keep in mind : Since this has had nothing done to it round edges lower it till you get to...

I used 160 or 220 they both got the corian back slick again then on a bench buffer i used carnuba wax. Also on some i did not sand at all left like a rough dimple tecture over the whole grip then...

Sorry i'm not understanding the question ---How far out are you sanding the corian grips?
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What gun are you carving for ? I had been working on some like 1911 scanned it in and was trying to get every thing work out on it but put it on back burner. Had cut several in 1/2 in. corian and...