The answer to the original question is simple: the Hornady comparator insert has a noticeably smaller diameter hole for a given caliber than does a Sinclair gauge. Does it matter? That's a slightly more complex question and may largely depend on whether you're a glass half full or glass half empty type of person.
As shown in the cartoon below, the two critical contact points (shown in
red and
blue, with the critical distance in between shown in
green) on the bullet ogive for uniform seating depth are 1) the point at which the seater die stem contacts the nose and "pushes" the bullet into the case, and 2) the point at which the bullet first contacts the rifling. If there is bullet length variance between these two points, there will also be seating depth variance unless the seater die micrometer is adjusted to account for it.
We typically use the comparator insert contact point on the bullet ogive as though it were identical to the actual point at which the bullet ogive first contacts the rifling. This may, or may not, actually be true. The Sinclair comparator insert holes are specifically designed to seat on the bullet ogive jat, or ever so slightly above the bearing surface/ogive junction. Presumably, this point is very close, if not identical, to the point on the bullet ogive that first contacts the rifling.
In contrast, the Hornady comparator insert with its
smaller hole seats noticeably farther out from the bearing surface junction on the bullet ogive. This means that you are not measuring the true distance from the base of the case to the point on the seated bullet ogive that will first contact the rifling. The Sinclair comparator insert give a truer measurement in this particular instance. However, because bullet length variance between the two critical points (seater die stem contact and comparator insert contact) can lead to seating depth variance, the closer the comparator insert seats on the bullet ogive to where the seating die stem contacts it, the less opportunity there is for bullet nose length variance, and therefore, the less opportunity there is for seating depth error to be induced by bullet nose length variance. So the real question is which (if either one) is the more critical aspect? For the most part, that's largely a personal preference issue and rather difficult and laborious to prove one way or the other in a statistically significant manner.
The real key to CBTO measurements are that you use the same comparator insert every time. As long as you do that, you will be measuring the actual loaded rounds you will ultimately shoot at a target to determine what seating depth gives you the tightest and most consistent grouping. Whichever caliper insert you choose can easily reproduce the same CBTO measurement to about +/- .0005" with reasonable care in its use. In other words, you only have to produce a given seating depth, then be able to consistently reproduce the one that gave you the best results. Either comparator insert can do that. Like the measurements we take to determine the distance to "touching" the lands, CBTO measurements are largely "relative", meaning the value obtained with either brand caliper insert may not be the actual "true" value. However, accuracy is less critical in the case of this and many other "relative" measurements for most of us. What really matters is that we can consistently reproduce whatever measurement we need.
So does the brand of caliper insert you choose really matter? Lots of things matter "in theory". Whether a given individual, their rifle, and their load can shoot well enough to distinguish certain very minute theoretical differences is another story. Only the individual can ultimately answer that question, and it's usually a ton of work and rigorous statistical analysis to do so. I own and have used both the Sinclair and Hornady caliper inserts. For a variety of reasons, I now routinely use the Hornady inserts, and they have performed adequately for my needs.
