steve-l,
Your rod method is great for verifying static alignment. When you actually shoot your airgun, additional clearance may be required to tolerate the fact that the barrel and moderator no longer form a straight line, due to barrel flex; or harmonics. if you prefer. Especially considering the typical skinny PCP barrel. The pellet will be travelling parallel to the section of barrel at the muzzle as it leaves, starting with the bore location at the pellet's release. Meanwhile the moderator may be travelling up, down or sideways, as the pellet is travelling down successive baffle bores. How much is such dynamic misalignment? More than zero.
Unless your PCP has a very stiff barrel, or is shooting at low power, perfect static alignment of the moderator bore to the barrel bore does not guarantee that every pellet will still have sufficient dynamic clearance. On top of that, the occasional pellet can wobble or yaw due to variation or imperfections in manufacture.
As you have impressed on us many times, the mods you make have perfect alignment with your airgun barrels. Such perfect alignment often does not exist when commercial airgun barrel, shrouds and moderators are combined. So, your range rod would be useful in condemning a poor combination of parts, but what is the solution in such a case? To measure and correct each aspect of each part until they have near perfect alignment. Not everyone has the tools or the skills to fix commercial airgun parts; so they instead use moderators with larger bores to provide more margin against clipping.
Your insistence that moderators have tight baffle bores because anything less makes them less effective, is like telling all vehicle owners to take their vehicles to a calibrated engine dynamometer shop, and to pay to have their engines "blue-printed", should they fall short of the best power and torque such engines are known to produce. This despite the fact that the vehicle owner had been perfectly happy with the on-road performance of the vehicle, as measured by their butts. In like manner, the majority of airgunners are happy with the sound reduction of their factory made moderators, despite the fact that it may be possible to improve that by 2 dB by fixing the "sloppy manufacturing" of commercial airguns parts and accessories.
Your model is like tuning drag racing car to produce the very shortest quarter miles time, to brag about it, just before the engine blows up and has to be rebuilt. Many people have simpler needs when it comes to the mods they attach to their airguns. They trust their ears; rather than buying and using expensive calibrated dB meters, in a controlled and approved lab setting, just so they can convince themselves or others that the mod they are using is the best, to the nearest dB. Often in engineering and commerce, the pursuit of perfection is the enemy of good. Settling for good enough or better than expected is not a mortal sin. Despite falling short of the very best possible with a given set of parts. All of whom have been remade to perfection.