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Ovarall Length

Even though I set my seating die up for the exact overall length suggested by the recipes I find that my finished rounds can vary by as much as +0.006.

Any ideas on how this can happen

I realize that my 1911 can be finicky on what it eats but I would like to resolve the issue so each round is consistent.

Are you checking your die settings with the shell plate full?  Mixed Brass?

Be sure to adjust the seat die with a fired case in station one to ensure consistant upward pressure on the toolhead. Most variation beyond this is due to differences between individual projectiles. The variation you describe is normal, and well within tolerances.

Are you sorting your brass? Use all the same brand and see if it helps. You may go blind sorting it, but when you are done it helps a great deal.

I have similar problems, but don't let it get to me that much. I use copper coated Berry's bullets , and whatever clean brass I have on-hand.
I usually load my .45 for an OAL of 1.235-1.240". IMHO, .005" variation "ain't too bad". So you are right there...... I have found that about 98% of my rounds stay withing these ranges. A "flyer" is rare.
I assume there is some variation due to 1) primer set 2) brass length/brand variations 3) Operator measuring error.

Use a consistent pull, develop a system, and measure every 10th round or so.

You;ll be OK
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