Finally had a range day to test out a bunch of loads in 4 different calibers, and everything hit the velocities that the load data lists under the max load before I even fired the max loads. Once I noticed this was happening I did not shoot my max loaded rounds, even though I had no other signs of over pressure.
This happened for each of the four calibers: 45ACP, 32ACP, .30-30, and 375WIN.
One caliber? Not weird. Barrel length difference between the data and my own gun could account for that.
But all four? Now I've clearly got a process problem because for 3 of the 4 calibers I was using have the same barrel length (and even gun) as the load data was developed on in testing.
All the velocities were collected with my new Garmin X1, so I trust the velocity data I collected.
My process for measuring powder has changed dramatically; I thought my upgrades would increase the accuracy and precision of my powder charges. I have a, new to me, RCBS UPM-3 powder throw, and I was using the M1000 scale to dial in the powder thrower. As these were my test loads, I weighed each charge. When the powder throw wasn't 100% on target, I hand trickled each charge or rejected it and dropped another charge. I assumed, therefore, my powder accuracy was correct to 0.1 of a grain.
I made ladders at 1gr increments in the rifle rounds, but everything was hitting max velocity before max load- the 375WIN shot max velocities at the second load for 255gr Barnes FPs using 34gr of RL-7.
I fired 20 rounds of 160gr Hornady FTXs in a LeveRevolution factory clone at the Hodgdon 32gr LVR starting load from my Winchester 94, and got the average velocity to match...but my spread was 104fps and SD was 29.6. The speeds swung wildly from high to low, and only the average velocity matched the load data -not a single shot actually came in at 2200fps. When I fired my Barnes 150gr TSXs I was immediately at or even above max load velocities with the starting load of 32.7gr LVR by 30-80fps.
Both pistol loads were Hornady's data using HP-38. Only the 45ACP loads worked about as expected, but didn't match published velocities in my 1911A1. The 32ACP loads swung wildly by 200fps at 2.2gr out of a pair of German Police surplus Walther PPs. (Sorry James, No 'K')
At what point in my process am I screwing something up, give my SDs were all in the 10-30 range, and velocities were higher than expected? I'm guessing it's the scale, but I followed all the steps to ensure anything magnetic couldn't be interfering with it. Even if it was off, it should have at least given me much more consistency given I hand trickled a lot of the loads.
Other data points: Used the lee factory crimp die on all of the calibers. All of these guns were older and all have higher-mileage barrels. My goal for the pistols was plinking ammo that cycles reliably at standard factory loads (consistent within +\- 25fps). My goal for the 375 is max safe velocity, it's got open sights and groups well inside of a white tail's vital area at 50 yards. My goal for the .30-30 was same level of accuracy and max safe velocity- none of these guns are going to win a precision rifle competition but 3-4inch groups were the norm from 5-shot strings. The 20 shot .30-30 group was 3in left on windage, but had a vertical string of 6in.