Make sure the engine is cold. Valve is closed, that is on the base circle of the camshaft. Yes use feeler gauges. Make sure you have slight drag or the feeler gauge, you'll get the "feel". Yes the cam HAS to be bolted in, that is the clearance your looking for, between the cam and shim.
Rebuild and then a HG 2000 miles later? Sounds like a good rebuild.
If it was properly rebuilt then bearing clearances should be fine, could be any of the things gaboon said. But until you get a hard gauge on there I wouldn't do anything rash.
Yah I hate how you have to buy parts to set your valves...Guess it's the nature of the beast though.
If your cam lobes are in bad shape you will prolly have to change the shims anyways as they'll chewed about as will.
It's like a petroloeum based cleaner/degreaser/solvent. I think Varsol is actually a name brand not 100% sure, it's whats in all are parts washers at work.
I say spring then. I quick dummy test is just unhook and plug the WG actuator singal line. Go for a drive, just let off if it goes high into boost, but it shouldn't if the diaphram(actuator) is fine, and the sping is cracked or worn, and exhaust gas pressure is opening the WG by itself.(Can you...
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