Sure there could be an error cutting the cap. But start simple first. See if the studs are bound up due to interference between the studs and the holes in the cap, 10 minute repair.
Doug

Doug I know they are so will be looking into that for sure

PM'd you crash I would like to hear back from you, I have the same problem with my 360, 17/32 hole is recommended when going to 1/2 stud but not sure if it may break into the bearing tab locator, I run my new out of box arp studs up in a lathe and found the shank of stud to be out of round aswel. I end up sanding the bearing to reach my clearance but have a 0.006 step on the other side that now has me thinking after reading this post. block was line honed, and clearance changed when caps were torqued up so maybe the caps have been machined bad.

I am doubting all these blocks were " machined bad". Look at what has been mentioned here, and you will find your problem.

With main studs, you may have to ream the main cap bolt holes slightly larger