IMHO you should shoot for final diameter on the first bore if possible, honing with a rigid engine hone isnt something I have done for aluminium surfaces but I imagine it would need special stones to cope with the material.
Ive used the bar to bore crankcase mouths larger when doing larger bore conversions, finish isnt perfect because the cutting speeds are set up for cast iron, but it lets me hold concentricity using a bored out block as a guide but Ive not been shooting for much in the way of tolerance, just big enough to accept the protrusion from larger liners.
For liners, I buy replacements with the same od and shrink them in, to go bigger I have to swap the casting for a big block unit anyway as there isnt enough support material around the liners with a stock block and it actually windows the casting at a certain diameter. You may find similar if your plouging off into uncharted conversion waters.
Ive used the bar to bore crankcase mouths larger when doing larger bore conversions, finish isnt perfect because the cutting speeds are set up for cast iron, but it lets me hold concentricity using a bored out block as a guide but Ive not been shooting for much in the way of tolerance, just big enough to accept the protrusion from larger liners.
For liners, I buy replacements with the same od and shrink them in, to go bigger I have to swap the casting for a big block unit anyway as there isnt enough support material around the liners with a stock block and it actually windows the casting at a certain diameter. You may find similar if your plouging off into uncharted conversion waters.