When it comes to cases, weights and volumes, I weigh every case, and spot check volumes. I use water for volume, with the spent primer still in the fired case. It was doing this that I discovered when the weights go down, the volumes go up, and vice versa. Not as much as you'd think, but enough.
I had a group of PPU cases that I intended to load up for hunting.
In 50 cases, there is a 10 grain non linear weight variation.
The only way to make this stuff consistent, was to vary the powder charge. (Well, there is another way, and that would have been at the bottom of a trash can.) After weight sorting the cases, I found a few in the middle that were really consistent. I wrote the weight of the case down and worked up a load with these. When I was done with my load development, I had an ES of 4 and an SD of 1.
If it wasn't for that, I'd have probably just tossed the cases, but I guess I needed a challenge.
I grouped these cases in 1.5 grain case weight groups. I Even color coded the heads with different colored sharpies to keep a little better track of them.
To compensate for the different case weights, I would bump the powder charge .1 grain for every 1.5 gr of case weight difference. Since I picked case weights from the middle, some would get more powder, some would get less.
(Now when I do this, I use cases at the higher end and work the powder down.)
I took a representative loaded cartridge from each case weight group, there were 5 different groups) and put them on target with a magnetospeed.
My original load for these cases was at 74 gr giving 3003 FPS average with an ES 4 and SD 1
These weight inconsistent cases, with randomly selected representative cartridges from each group, shot like this:
CW= case weight PW= powder weight
1). 238.2 CW 74.7 PW 3006 FPS
2). 239.3 CW 74.4 PW 2998 FPS
3). 240.0 CW 74.3 PW 3006 FPS
4). 247.3 CW 73.9 PW 3002 FPS
5). 248.6 CW 73.8 PW 2998 FPS
AVG 3002
ES 8 SD 4
They all went on target with 2 fliers for fouling and 3 making a .758" hole for a .450" group.
Now, is it ES 4, and SD 1 ?
No.
Is it bench rest quality?
No.
Here's my favorite question:
Is it good enough for who it's for?
YES.
I always intended these for hunting loads, and they will do just fine for me.
I worked hard on it, I'm happy with the results and I learned something along the way. You can actually vary a powder charge to compensate for changes in volume as measured by brass weight. It won't be exact, but it will be close.