One thing about what you said about changing the HT by creating heat on the edge. You have to be quick and keep a wet rag handy to wipe the blade down after swiping it across on both sides. Kyle you said you use a worn out 400 grit belt for finishing? No No No, use a sharp belt for putting the edge on and when you are sanding the blade use light pressure always and be patient, remember it's only to finish the edge and an edge is real easy to overheat. For sharpening I cannot over emphasize using fairly sharp belts, they do not need to be new, just not worn out as that maybe is why you are getting the bur. What grit is your finishing wheel by the way?
I get rid of burrs by hand sharpening, so I can't help you there Kyle, I think it is the best way to finish an edge. My first instruction on how to sharpen by hand was simply pretend you are trying to slice an apple real thin. It works if you can maintain your angle. A big if for some folks.lol
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