67/68/69 cuda dilemma

I like your system you have laid out there. Did you have to open the gaps up much for the KB pistons? Gapping rings can be a pretty time-consuming task, and better done with no distractions like you said you did it. I finally got a fine grit fishhook sharpener to use to debur the ends of the rings after filing the gap.
According to KBs chart based on my bore of 3.940" the top ring needs to be at minimum. 026" gap. Mine are all at .018". So yep, I need to open them all up a little bit. Since I didnt have one, I bought a manual ring grinder off evilbay. They stated the #2 compression ring was not as critical.