In the end, what I chose to do was stay conservative and utilizing some hand tools and a makeshift jig, I filed the galled aluminum away off the edge of the left hand bottom bracket shell. I took it just down to the original edge where the spacer of the stolen BB butted against. I used digital calipers frequently around the entire circumference to check the width of the BB shell. To finish I inserted a large bolt thru the shell which was stopped on the right side by a large washer. To the bolt on the left I had prepped one side of a washer with some Emery cloth, which faced (literally!) the left edge of the shell. With the calipers I had marked on the bolt 68 mm from the inside of the right hand washer. Here I ran a length of electrical tape around the circumference of the bolt. This acted as my 68 mm mark and because the washer was just big enough to go over the bolt threads would stop the left side washer and. nut from advancing past 68 mm. I rotated this assembly about 6 times rubbing the left hand shell with the Emery cloth. Coming away, the shell measured within a few hundreths of a mm. If memory serves, the largest devience was .03 mm.
After approximately 250 miles the Shimano external bearing BB seems fine. I installed a 2x10 drivetrain (Deore M6000 crank, 34-24 with XT derailleurs and shifters). Last week I installed 38-28 chainwheels for a little more top end. While the crank was off I did a pretty thorough investigation of the BB and found both sides to be very smooth. Only about 250 miles I would guess, but I ride daily in all conditions. So far, so good. The bike is dressed up a little higher end than when it was stolen and stripped. I've added a Fox Forx front end. XT hubs laced to Mavic 321 rims. The front der is XT (M8020). That's the side swing style and makes the shifting noticably lighter and the throw seems reduced, though that could be the result of 2x front drive when I've previously stuck with triples (8,9, & 10 s versions on different bikes the last three years since my lifelong love for bicycles turned hardcore). Anyway, I like what's developed out of some negativity.
Some notes: I have Shimano hydraulic disc brakes now (Deore M6000). I've run both hydraulic and mechanical disc brakes over the years, mostly on dedicated all-mountain bikes and one or two transient day to day bikes. Mostly though, it's been V-brakes. On the setup that was stolen, I had Shimano Deore V- brakes with extreme condition pads. From a performance standpoint in fair weather, I believe the V-brakes are equivalent to discs, and if I had to say, I stopped faster with the VBrakes. When cost and other overall parameters like maintenance cost are included, V-brakes become a far superior value. The set-up of the V-brakes can be a POA, but when they're dialed in, a disc brake won't shame them in any performance category. And a 5mm Allen wrench compared to a bleed kit, spacers, rotor trueing, fluid. They got us by the short hairs on that deal.
Suspension systems need to come down off their high horse too. Nearly a $1000 for an overly complex system requiring two different fluids, aftermarket parts and kits to get it dialed in right for the individual and a maintenance schedule with frequencies more often than I pee, and, again, the cost of said maintenance. "PLUSH is more than just a ride characteristic," said the Fox to the Rock Shox as Marzocchi & Manitou toasted their champagne to that!
Power to the people! I'm off to ride.