I have stopped using Rev No 3 glue because I agree it is inconsistent. Some blades that are laquered, it does not matter how many layers of Rev No 3 glue I apply, the rubber just does not stick!
I only use Butterfly Free Chack Pro II now. It is thick and dries really fast. I always apply two layers to the rubber and two layers to the blade. The worst thing that can happen is, the rubber does not stick and then you have to take it off and do it again. If so, you might end up using a perfectly new rubber due to the stupid glue.
To save a couple cents on glue while ruining a perfectly new rubber that costs $30-$65 a piece does not make sense to me.
As for as glue removal, it is actually dependent on the rubber. For example, DHS (or any Chinese rubber with dense sponge) and Butterfly rubbers, you can remove the glue easily without damaging the sponge. I am currently removing the glue from a sheet of Butterfly Glayzer and so far so good. Butterfly has some numbers printed at the bottom of the sheet so around that area, you might get little holes coming off. But the rest of the sponge stays intact while I am slowly removing the glue as I am typing right now.
However, many ESN rubbers I use (with the worst offenders being Rakza 7 soft or the Xiom Vega Series or C-1), then you remove the glue, no matter how careful you are, the sponge will always end up with some holes here and there. For those rubbers, I just take them off the blade and not remove any glue. I just apply one layer of booster and one layer of glue, and I stick it back on the blade maybe 1-2 days later. I don't have the time or the desire to remove glues from those sponges anymore. I just know I will not be happy with the end result. So leave the glue on, apply one layer of booster and put it back on the blade 1-2 days later.
It is not the glue. It is the rubber and the sponge.