RE: Problem with OAL inconsistency!!!
How do the rounds shoot?
I've seen Hornady V-Max bullets vary in bullet length (base of bullet to tip) by as much as +/- 0.005" out of the same box of bullets. I once noticed the same problem you have with my handloads and it drove me crazy, so I started measuring the bullets themselves and made this discovery. Nosler Ballistic Tips are much more consistant, with the variance in length being hardly ever more than +/- 0.002".
I got he Stoney Point Bullet Comparator and found out that the bullet seating was very consistant at measured on the ogive, with +/- 0.0005" the normal tolerance using Redding dies, even when COL (tip to base) was seemingly way off. The loads did shoot very well. I think you're psyching yourself out. Put the loads through paper before you pull your hair out wrestling with minutiae.
Good Luck,
Mike