I do not doubt that people who measure with calipers for every pen get good results. For me, the bushings are more reliable. For example, if you measure the center band adapter on a cigar ultra kit, the measurement that you get is larger than the corresponding bushing's diameter. The reason for this, I think, is that the adapter has a round shape. So are you measuring at the top, bottom, or middle of the round adapter? I don't know, but I use the bushings and the fit has, so far, been very precise every time. There are other examples, but the point is the same. Sometimes the measurement with the calipers is harder (at least for me) to do in a reliable way than simply counting on the bushings. Another issue is the shape of the pen near the nib, cb, and cap. If you are using B2B, then your point of measurement is straight and you can rely on your measurement. If not, you can take 3 or 4 measurements on a sloped surface and get 3 or 4 different results.
I've made perhaps 40 pens, so my experience base is not that great. On the last 25 or so, I've not had even the slightest trouble with fit. I do check the bushings to see if they've worn down, but so far none has shown any signs of wear.
More than likely I just don't have enough experience working with the calipers. I've worked hard to get some level of competence with the bushings and don't feel like starting over on a learning curve with calipers only.