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The difference in rolling resistance that you get from having two same sized, different sets of tires is probably equivalent to the difference in rolling resistance that a small variation in tire pressures will cause. Since people don't check their tire pressure every time they go out, there's usually a few pounds difference between tires, but that's never seemed to cause any damage, so I wouldn't worry about it.
The size difference caused by the wear on one of the sets shouldn't matter too much as long as it's not drastic.
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