"Wornout" die
After some experiments and the guidance of a real engineer, the following was discovered:
1. Using a "bore scope" and a coordinate measureing machine we determined that the die may be worn but is showing no signs of wear being the cause of the difference inseating depth. Strightness of the loaded round yes, but not seating depth.
2. Using a force gauge and neck turned brass (turned to .0006" on a very precise lathe) we deterinmed that SOME of the differnce in seating deepth was due to the variance in neck tension.
3. By sorting through 250 bullets we found a sample group that were as idenitcal as we could measure (diameter, length of bearing surface, doughtnut at the base ogive etc.) I seated twenty bullets with less than .001" of differnce in seating depth.
4. By switching to a custom bullet (name withheld at the request of the maker, not any one of the popular custom makers however) and seating random bullets in to the neck turned cases we had less than .002" of difference.
So the die wasnt worn out and, as my engineer buddy said: "If you would buy better bullets you wouldn't need my lab on a weekend when we could be shooting."
Thanks every one, the quest for accuracy never stops.
Arrowmaker