Anyone running one this much over in a very mild build? I have one with almost no miles but it was in a fire and water rusted a couple cylinders and the machine shop said the worst one needs to go .060 over, they don't have a sonic tester...

Sleeve it.

Agreed on the Sleeve. .060" is a huge stretch. And yes, you should have it sonic checked.

New BGE standard bore honed with a torque plate is 2k

Sonic to be sure,
Shine a light down in to the water jacket if there is a web connecting the bottom of the cylinders to each other , it should be able to go 4.165 , older Apache blocks DO NOT have the lower connector. and are like the Eagle 5.7s, were .02 is ok .030 is fine , 060 needs to be sleeved. Issue your going to find is no off the shelf piston at 4.15 bore.
I have a 2016 here right now that's at 4.185(.095 over) running a 4.05 crank, 6.20 rod and 1.055 Pin height piston , makes a hair over 700hp with thinnest spot being # 1 thrust side(12 o'clock valley side) .125 at the top and .165 Mid point (3.5" down bore) 2015 & 2016 will take .060 the 17 & later blocks I sonic to double check, they seem to be like the 09 -10 6.1 blocks with core shift being an issue.....There is thread here on Moparts , where some guy MatW ? had posted some Hellcat block Sonic #s. ..........2017& later 6.4 blocks are all the same.
Early 2014 BGEs don't have the Web at the bottom of the water jacket., they are the same cylinder core as the Apache but have more water jacket capacity.

It's a 2022 BGE block.

Since there are no stock replacement pistons for that bore size now I'm contemplating a 4.150 custom flat top, I already have some 6.250 rods with 2.1 rod .927 pin and a stock 6.4 crank that needs machined for some light scoring... thinking about offset grinding it .025 to build a 405 CID would be nice and easy to do with 11.5 compression and a very mild cam for down low TQ in my work truck....

The BGE is beefier than the SRT 6.4 block, would be nice to know just how much beefier it is!

[i][/i]what is a "BGE block"?

https://www.dodgegarage.com/news/ar...ngine-quick-reference-guide-part-iv.html

With the advent of the 6.4L HEMI truck engines, a thicker block was cast and used across the entire engine platform (that included 392 HEMI engine-powered cars and SUVs around 2017-2018). These blocks are known as “Big Gas Engine” or BGE for short. Both “BG” and/or “BGE” will be cast on the side and/or on the back of the block. These blocks might be hard to come by if you’re looking for a used 6.4L/392 HEMI engine, but their high nickel content, superior casting and slightly shorter water jacket (which provides increased cylinder wall rigidness/strength) are a huge bonus for serious horsepower engine builds.

BGE is used in the hellcats and 6.4 trucks, then somewhere during 2017 they were using it for the 392/6.4 cars as well. Pre BGE 6.4 SRT blocks were thinner to keep weight down!