The trick to measuring holes with calipers is to do it while it is spinning in lathe. Been doing this for years and it is very accurate. If you try to measure when stopped it is hard to get calipers into the hole right and the measurement is off.
Well, I can't say as I've tried that one.
Keep in mind that I'm teaching others to do the work and that sounds like a very specialized method. One that I'm not sure I would feel comfortable teaching someone else who doesn't have the years of measuring experience that I do.
I will say this though. The plug gauges are absolutely the best thing I've done when it comes to making these kinds of parts to fit. I was aware of them but had not tried them out when Jim Babcock recommended that I give them a try. They work very well.
I think, often, we get stuck on trying to hit an exact single dimension, like .382". But, in reality, there's a range of size that will not only work, but is actually ideal. Too small and you don't give the epoxy enough room for strength, and too big and you lose bonding strength as well as proper location.
For example. We've recently started to use the modified thread 3/8-10 joint pins with an alignment barrel. I buy them from Tommy Migliore. They have a barrel diameter of .381". Logic will tell you that you can't fit a .381" steel pin into a .381" hole. So, what is the correct size for the hole? By using a pair of plug gauges, you create the limits or boundaries. Obviously, you want one pin that will fit in the hole, and one that won't fit. For our joint pins, we use a .382" gauge for the "go", and something like a .385" for the "no go". So, while machining the holes for the joint pins, the technician is constantly measuring with these pins. Obviously, if the hole gets too small, the small one won't fit, and if it gets too big, the large one will fit. Either one requires an adjustment to be done. Most people think that, with our CNC equipment, we can just set it and forget it. But, especially when dealing with wood, the numbers will move around a little. In order to hold the right dimensions, you just have to keep checking. We use all carbide tooling, but still deal with tool wear on a regular basis. Especially when machining phenolic.
Royce