my guess is neck tension because I was using different brass from different lots all mixed together.
All bullet manufacturers have some base-ogive variability across lots but I notice it more with longer, heavier bullets vs the small/light stuff. Berger and Hornady are more consistent than Sierra. I ogive sort to eliminate that as a source of inconsistency in the final product
Using brass from different manufacturers/lots is never a good idea, as you know...that said, it is possible to arrive at the same neck tension between different brass, depending upon other things. Point is you don’t want to just guess....
Here’s what I suggest:
1) Measure base- ogive lengths until you have 10 bullets with the exact same dimension.
2) Take one of those bullets and run it into your rifle using the Hornady oal gauge and modified case to jam length, record that length
3) Prep you brass as you described above (you may also want to weight sort until you get 10 pieces within say .002 grains of each other)
4) FL Size your brass to desired cartridge-chamber headspace (bolt guns, I do .001-.002)
5) Measure for run out and neck wall thickness if you a concentricity gauge and neck wall gauge.
6) Take all other measurements required for determining neck tension
7) adjust your seater die based on desired starting jump using the jam length recorded earlier (I start Berger target hybrids at .005”)
8) Prime, Charge and seat your bullets, measuring for neck tension - I usually shoot for .002“-.003“
9) Take a final case head-to-ogive measurement with your comparator to see if you have any material differences in seating depth across the 10 loaded rounds...measure for bullet run out using the concentricity gauge if applicable.
Any variance > .001 across all 10 would have to be attributed to something other than your components and process since you would have adequately controlled for raw materials and process variance. This is when I would consider buying a vld seating stem for your die, pulling and reseating them with the VLD stem to see if that solves the problem.
Others may chime in with addl tips as well.
Good luck with it!