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I don't see how you can follow the hole any cutter on a vertical mill will just cut a new hole and unless you can centre them with sufficient precision and then index the job correctly then alignment will always be an issue.
If you want to carry out this job without line boring then you either need clearance around one set of dowels or you need to clamp the cases.
If you have enough clearance the cases fit together and all looks good but the 'pins' don't prevent a small amount of relative movement.
Unless you press the cases together then there must be clearance.
An m6 fit on a dowel which is what would be recommended by the relevant ISO Standard needs an insertion force of 15kg.
The same ISO Standard recommends a 0.003" diamteral clearance for a 'slip' fit which is a radial clearance of 0.0015" or 60 microns. This is more than enough relative movement to allow fretting of the case mating surfaces.
When you 'pin' a case that can easily be assembled/disassembled there will be clearance around one set of holes which is why I question the entire process.
It looks good, it sounds good but I don't think it has much effect.
I come back to the two questions I always ask about shuffle pins.
What creates the forces that cause shuffling ?
What is the precision to which the pins are aligned?
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