There are 2 thoughts on the area of a port. One is like you say, rolling it out. The other is viewing the port as a window looking straight at it as a flat opening. Talking with Brian Callahan, neither has been accepted at the norm. Personally, judgement makes me think that the port is really just a flat window rather than a curved window.
The best way to measure the port seems to be either the way you are doing it or, putting a piece of paper inside the liner, putting a flat piece of shim stock or something as a backing and then using a sharp pencil to draw the port. Then measure across the port to get the exact measurement to determine the amount the pencil missed by and then draw a line outside the pencil tracing that distance.
Maybe a cross check would be good. The final thing is to draw it in AutoCad and use the Mass Properties to calculate the area of all the ports combined.
Maybe we can get someone to make a mandrel and cast some Carbon pipes from that after the pipe has been designed.