Ned Ludd
Silver $$ Contributor
There can be a number of reasons to explain this phenomenon, many of which have already been covered above. One thing I would point out is that the bullet length inconsistency that might be part of the problem does not lie in the BTO dimension. It would be caused by inconsistent bullet nose length between where the seating die stem contacts the bullet out on the ogive near the nose, and the point on the ogive close to the bearing surface where you caliper insert seats. For that reason, sorting bullets BTO will likely not solve the issue. You might try sorting bullets by OAL and see if that helps; it will do more to actually sort bullets with length variance in the problem region between the seating die stem and caliper insert contact points.
One other thing to consider might be your approach to seating bullets. Regardless of whether there are other underlying causes for your seating depth inconsistency, I would suggest setting the seating die micrometer so that none of your loaded rounds are ever shorter cartridge base-to-ogive (CBTO) than 2.175". From what you described, that will necessarily mean that some will be longer than 2.175". However, you can always put those rounds back in the press after measuring them for an additional stroke, which in my hands will usually seat the bullet from about .0005" to .0015" deeper. If necessary, you can even dial down the micrometer an additional .001" or .002" as necessary, based on your CBTO measurements, then dial it back to the previous setting for the seating the next round. The key is that none of your loaded rounds will end up shorter than your target CBTO length. Yes, it's a little more work that way, but you'll end up with consistent CBTO values for all your loaded rounds. In the meantime, you can figure out what the underlying cause is so the you can correct it.
One other thing to consider might be your approach to seating bullets. Regardless of whether there are other underlying causes for your seating depth inconsistency, I would suggest setting the seating die micrometer so that none of your loaded rounds are ever shorter cartridge base-to-ogive (CBTO) than 2.175". From what you described, that will necessarily mean that some will be longer than 2.175". However, you can always put those rounds back in the press after measuring them for an additional stroke, which in my hands will usually seat the bullet from about .0005" to .0015" deeper. If necessary, you can even dial down the micrometer an additional .001" or .002" as necessary, based on your CBTO measurements, then dial it back to the previous setting for the seating the next round. The key is that none of your loaded rounds will end up shorter than your target CBTO length. Yes, it's a little more work that way, but you'll end up with consistent CBTO values for all your loaded rounds. In the meantime, you can figure out what the underlying cause is so the you can correct it.










