While dial bore gaging my rod bearings, I noticed after torquing the caps that the crush on the rod bearings is yielding the bearings at the joint and raising an edge. Anybody ever see this happen before?? It has me concerned

 

If I understand what you're saying properly, I had the same problem once. It happened on a main cap but same deal. As I tapped the cap over the studs the bearing shell dropped out of the cap a hair. When I torqued it, it was misaligned. If you pull the bearing back out, is it twisted?

 

File the corners of your caps & rod at a 45* angle to deburr them,but do it lightly and with a mill file.(fine) Do your main caps and block too.
It's always been automatic with me to do it.

 

If I understand you correctly, you want me to put like a .015" X 45* chamfer on the cap and the rod (4 places). Is this to make some room for the bearing halves to yield on the OD and not affect the ID dimension at the split???

 

It takes any burr's off that may be holding the brg out of it's proper position.
A .015 x 45* would be good.