[mikedsilva]

For what it's worth, I use boregauges, micrometers and plastigauge to double check.

For a street/home build, plastigauge is more than acceptable. I've never had success being able to do the rods with plastigauge though.. not sure how people manage to torque the rod bolts without the rod moving.. maybe that's me? I always use mics and bore gauges.

I never re-use bearings. I've only once or twice come across bearings with zero marks or wear. And even if they look perfect, I just cannot bring myself to re-use them. For your rods, def do not use the Glyco bearings. Use the Automobile Associates style or if available, look for ACL bearings. They come in std size and "extra clearance" sizing and they are extremely accurate.
For the mains, the Glyco tend to be ok but I usually go with Gen Porsche GT3 main bearings.

When you bolt your case halves together with the crank, make sure to use the #8 bearing too. It is the "locating dowel" at that end of the case.

I target 2 thou clearance on mains and rods.

As sturdy as the aluminium cases are (compared to Magnesium), I've never come across one that measures within the Porsche spec of 65.00-65.019 mm. Never.

People say that Alusil cannot be re-ringed cos Wayne's book says so. Others have done it. Some successfully. Some not. I have not come across a client willing to take the risk yet. So I have the cylinder replaced or re-plated with Nikasil and get replacement pistons and suitable rings.
If you look at the parts listings on this site for rings, they say they are suitable for BOTH Mahle and KS cylinders.. but how can that be possible?

Others have said they buy them from here, but when I have asked for part numbers so I can order some, the trail goes dry... I tried speaking to the reps at this site, but they couldn't assist.

As for Alusil being no good, well, it is used widely in lots of other makes and lots of other Porsches. I recently rebuilt a 3.0 with Alusil.. it had travelled 250,000 kms. The cylinders looked like new and the rings were also in great condition.