Well....
This might end up being ridiculed, but what I did to test the gas port diameter of my Kvar barrel assemblies was to use a small piece of steel wire (in my case from one of those cheap lawn flags that you can buy at a hardware store), and put it in the vise. Squeeze and measure until you come up with the right gas port size plus a few thousandths. File slightly if you overdo it. Use your calipers to measure. Then, carefully slide the bent wire down the gas port hole and into the barrel. If it doesn't fit, you should be gtg. FIle down to the proper diameter, and it should pop into the bore with a little wiggling.
Hopefully that's not completely stupid, but it made sense to me.