[Big-Foot]

Hey there Paul - Good to hear from you! Say howdy to the folks back at ffcobra for me!

Excaliber is right - measuring correctly is almost an art form and requires exceptional attention to detail and feel... I've been doing it for so many years now, it is almost second nature, but I still have to focus my complete attention so as to not overlook something. That's how you gain repeat business and racing championships!
In regard to Plastiguage:
I did a bunch of testing with different crankshaft main bearing journals and rod journals a number of years ago during a slump - just to see how accurate Plastiguage really was. I found that the AGE of the plastiguage was more important than anything. Fresh plastiguage would give you a measurement that was accurate to the .00025" when fresh. When it was old and brittle, it would always read high on rods (by as much as .0005") and would read about the same on mains. As strange as it seems, rod caps would seem to flex a little with the old brittle stuff.

The alternative to plastiguage is using micrometers and snap-guages. Understand that when you first seat a bearing, you are "crushing" the bearing into the saddle - the first reading you take with a bearing that is freshly crushed will give you the best reading. Once you un-torque and re-torque the bearing cap, you will get a different reading (off only by 10ths of a thou, but different).. Positioning snap guages and then pulling them out of the bearing without moving the pin can be difficult for some folks - then you need to read the pin length with an outside (Caliper) Micrometer without compressing or moving the pin. Honestly - it is a PITB even for those of us that have good equipment and know how to use it. I use both methods of measuring, depending upon the build and the type of rods and fasteners being used. Many other shops in my area do the same thing.

In my opinion, there is nothing wrong with Pastiguage as long as it is fresh. Make sure you wash off the residue of the smushed plastiguage with lacquer thinner and use a liberal dose of assembly lube before you re-assemble the bearing for good.