MIMF

I have the .060, .080, .120. In the larger sizes, should I add .010 to the size to allow for glue-up of purfling combinations? So a .160 would be a .170, etc.

Use what you have and if you find you need other sizes then make that effort. The depth of cut can and will vary somewhat depending on how you hold things and how much pressure you exert. I often have to true up binding cuts after they have been cut.

You can always add a layer or two of tape to the bearing. It's a good way to keep softer woods from getting marred as well.