26" barrells are standard on space guns used in Highpower using standatd uppers, even with them slotted out for a side handle. John Hollinger uses a +2" extended gas sysetm on those though. THe gas block is .936 and the barrel is .925 or so to the muzzle. Under the handguard the diameter depends on the clearance of the barrel nut you use, but its usually less than 1", IIRC about .950 or so.
As far as your fit of your barrel extension to your upper, I feel that more important is that the face of the upper be square to the bore. You can check this with red layout blue and by turning up a mandrel/lapping bar to ensure this, so that the barrel nut tightens the extension against a square surface. THe only upper I ever had that would not shoot had a small burr, about .002 or so, and a small dip about the same opposed from each other. Lapping that square turned a 2-3" upper into a .75" upper.
I have shimmed them in the past, but have never used a custom ground one. There may be something to it, but I have never seen the results.