You didnt say if you were getting the "spark" while the switch was mounted or hanging out of the box. This is a picture on how it should be connected.
https://www.hometips.com/wp-content/uploads/2012/07/3-way-switch-wiring-diagram-1.pngEven if you dont use a pigtail on the ground, with the switch mounted the ground is good enough. With the switch hanging out you can test the circuit by flipping the switches to see if it sparks or pops a breaker.
First be sure that it is wired correctly.
Second, even if you dont think you could have damaged the wires coming into the box by switching the switch check them. Loosen the clamp that holds the cable and give them a tug to see if there is some slack and you can pull a bit more into the box. Inspect the cable, tape off any iffy spots and tighten down the clamp.
When "reforming the ends" be sure to only have enough wire exposed to wrap around the screw. Any more could leave enough to get a ground connection when mounted. Once Im sure I have the plug/switch wired right I'll wrap a bit of tape around the unit to cover the screws to be sure it cant short to the box if jostled.
Next test the switches while they are hanging out of the box. If no sparks, mount one and test again. If you have sparks, unmount that one, mount the other one and test again. If sparks again, your wired wrong or your grounded some place else.
And yes, if you are only touching one wire at a time and NOT grounding yourself it is easy to do this with out shutting off the power. However everyone slips and a good zap keeps the resect strong in all of us