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Please post a list of equipment you are using, as it will help us figure it out. are you sure that the seater is locked down and not moving? Die holder moving?,
All of the equipment is from the Lee anniverary kit. The Dies are also lee. so far all I have been loading is .25-06, 85gr CT bullets, and Winchester cases.
Measure the lengths of the CT bullets. See if you have variations there. Also, check your seating die to be sure it is not pushing on the tip, but rather where ogive angle of the jacket starts. If you're pushing on the polymer tip, you could easily get a variance of + or - .01" dependig on the entry diameter of the case. -Steve
I would HIGHLY recommend you get a tool to measure to the ogive, such as the hornady tool. that will take the guess work out of it. http://www.midwayusa.com/viewproduct/?productnumber=231904also, check your calipers, if they are loose or you are using different amounts of force, you will read different. the better the caliper the better they usually come out of the box. the cheap harbor freight ones I have had have been terrible until properly adjusted, then they work fine until they wear out (I go through about one a year from wear)
1-3 mils is down in the range that can easily be caused by sloppy calipers or inconsistent form when using them as well...