Rick, every competitive shooter I know will tell you they can feel variations in the bore of a rifle they're cleaning with a rod and a patch. I know I can! I can also see variations in the lands with a bore scope on many barrels I own and I'm not superman. Most of these barrels shoot fine, some with obvious flaws will outshoot some with no apparent flaws, go figure. I don't think the top shelf barrel companies run around lying or bullting us about the quality they try to attain but sometimes mistakes happen and they get missed. Never forget they're in business and have to make a profit like all the rest of the businesses out there.
While I won't take issue with your conclusion, you will not convince me that what you feel when pushing a cotton patch through a bore is a variation in bore diameter. You can choose to believe what you like, but the idea that you can detect a variation of .001 or .002 pushing a cotton patch through a bore is simply not believable. Seeing problems with a borescope is another issue altogether, but that's not what we are talking about. Dave Tooley says that in nearly 6,000 Bartlein barrels (Pretty sure that was the barrel maker), he's never had a bad one. BTW- I know a little about business and you don't keep customers by bull$hi!!g them about the quality of a product. I'll agree that once in a great while a mistake might get out the door, but I'm unconvinced that pushing a .22 LR bullet through a hand lapped bore will cause it to show up.
As I said, I do not have a dog in this fight. I just buy barrels and shoot them. I wanted to see what folks had to say and now I've seen that. We can choose to disagree.
Rick