Contact Mike Bellm himself about this. He is both knowledgeable and more than willing to explain things fully.

mike@bellmtcs.com

$bob$

A couple of things come immediately to mind. Fist is lube, did you use cutting oil as you reamed the barrel. You would need to use lots of it to keep the tools from galling or over heating. I know it doesn't seem like enough heat can be generated by hand, but it's possible. The reamer should be tapered on the end, so as to follow the original hole without much trouble.
Second, is to go slow, cutting just a little at a time. Trying to make to big a bite on each cut can cause the rough finish you describe.
Another option is, that years ago someone made a Contender hinge pin that had screws on both sides and a slotted sleeve between them. You inserted the pin and tightened the screws to make lockup just right. I would imagine it is still being made somewhere, but I haven't had a Contender/Encore for a long while, so I haven't kept up with such things.

I have tried that very thing, his e-mail box is full, can not get a message in to him, and have left a message on the board as well. Very unusal for Mike, but then sometimes life gets you all balled up, that I understand all too well.