Sorry for the thread drift...
In the entire story there seems to be a lack of something important. Nobody has pinned it down: A lack of Knowledge, experience, measuring capabilities, accurate measuring tools, judgement, patience?
Certainly something missing to make an obvious problem such a mystery yet a pattern of problems experiences?
Cutting bores that cannot be readily measured is odd, in my opinion. Why do it that way, because it is easier, quicker?

I'm not down on reboring, just someone in a big hurry to get the work out, cutting throats undersize then learning about it because of repeated pressure problems?
Not my barrel or my client's, thank you.