Far as I know, Joe, pellet sizers only work in the other direction. Regarding the barrel I.D., maybe Charlie or Peterdragin can give you a definite answer. Do bear in mind, pellets ain't bullets! Resistance isn't always a good measure. Look at the pellet instead. Are there consistant rifling marks on the pellet? The other thing to do is try different pellets. How is the accuracy and consistentcy? Also remember, when the pellet gets hit by the air blast from the piston, the skirt gets blown out against the rifleing. At least that's what's supposed to happen.
You got my curiousity up, so I just pushed a couple of pellets throught the S1K I'm using. The largest pellets I have on hand are JSB Exacts with head diameters rangeing from 4.50 to 4.53. I just ran a 4.52 and a 4.53 through the barrel. The .52 barely had any resistance, although it didn't fall through. The .53 was slightly tighter. Both had nice, even rifling marks on the skirts. Interestingly enough, the .52 shoots the best in this rifle, but I've only done one very quick test last night. Check my post on the Shoot out.
You don't have to have a chrony to get a good idea of velocity. Look in the Library under Airgun Calculators. There's a velocity estimator there that uses POI change over different ranges to determine velocity. I haven't tested it against my (brand new!) Chrony, but will when I get a chance. Sorry I got so long winded, hope this is some help.
Dave