@Green Chile Thanks I appreciate the feedback
@Ontario Hunter
I have done a more than a reasonable amount of competitive shooting, so I can answer some of these questions... Kind of... The kind of, is because it varies a lot from rifle to rifle, mostly depending on how your chambers were cut... When I built up my precision rig, I custom ordered the reamer, and had it cut with that, knowing it was to my specs, and that it was the first chamber cut with that reamer.
So... To answer your questions:
1: "How much is accuracy/reliability at that range affected by a bit of bullet movement in the case?" Ans - This depends again on your rifle, but here is how you can check it, and specifically, here is how you check it in a comparative sense. Prep up 40ish brass at the same time, so they are all as consistent as you can. Take the first 20, and put them into 4 groups of 5 rounds each. What you want to do is make 5 rounds that sit about 25 thou back from the lands (if using solid copper rounds, they need runup if lead, make them just kiss the lands). Then group 2 will be 20-25 thou shorter, group 3 45-55thou shorter, group 4 70-75 thou shorter. When you shoot those groups one of two things will happen. Either almost nothing, OR you will find your groups trending toward or away from tightness. If you do this enough, you will find the optimal length for accuracy in your gun. BUT what you will also do is determine exactly how much accuracy variation occurs from a different COL. In my experience a few thou can make a measurable difference, but it takes like 50 thou or more to start getting unacceptable results.
Then take the other 20 brass and load them up to the length of the most accurate group from the first test. Crimp 10 of them, leave the other 10 un crimped. Now shoot those and compare. Your crimp might make a big difference, it might make almost no difference. BUT, I have never seen a crimp make the groups better, the best case scenario is that they are not much worse.
2: "Curiously, I found some of these old Barnes X bullets seat differently when nothing has changed with the dies."
Ans - Nothing wrong with that, provided that it is only a few thou, say +-5 or so. The reason for this is based on how the measurement is made. When you measure COL with your calipers, you are measuring base of the case, to tip of the bullet. BUT, modern dies DO NOT seat based on the tip. They seat based on the ogive, so that they do not deform the tip. So that few thou variation you are seeing is the difference in the actual bullet tips themselves. How do you check this? Well, take 10 bullets, measure their lengths (just the projectile), and you will see that they are different lengths. Now load them in cases that you have measured that are the same length. You should see that the variation in overall lengths now roughly corresponds to the bullet overall lengths. Though there will still be some differences, because the ogives will be slightly different. Guys that shoot F class matches and stuff will actually buy bullets in massive quantities, so they can sort bullets by their bearing surface length and ogive characteristic and stuff to make lots of bullets that are more similar. I don't not recommend this for DG rifles at all. Because it is a super waste of time. Honestly we are aiming for 4" groups off sticks at 100. Not sub MOA, which is an expectation I have had to temper in myself.
Here is an example of a test for the 143gr ELD-X bullet in my 6.5x55
Kissing the lands - .58" 5 shot group
5 thou behind lands - .51" 5 shot group
10 thou behind lands - .32" group with a called flyer
15 thou behind lands - .18" group with another called flyer - I am human
20 thou behind lands - .67"
25 thou behind- 48" and a suspected flyer.
The point is that you can see it get tighter, hit an optimal length, then open up again. Small changes in length can affect accuracy. But in all these examples, that max variation is still only around .5" over 25 thou of seating depth. So I would wager unless your bullets are shifting A LOT, its not affecting accuracy that much.