Man .... you are way overthinking this stuff. The max. length doesn't mean squat, it's just so the round will be able to fit into the magazine. I've loaded tons of these things, a long time ago, so I'm not exactly up to speed on it anymore.
I'll leave my contact number in a PM if you'd like to give me a call.
I think I’ll clarify what I said yesterday.
First, there’s nothing wrong with over thinking something. I tend to do the same thing myself, which is better than not thinking enough.
Too much OAL would not be good because that could cause the bullet to be crammed against the start of the rifling, which could lead to over-pressuring. They might be too long for the mags also.
Ideally there should be approx. 1/16” to 1/8” of gap (freebore, or throat) between the bullet and the start of the rifling when the round is chambered. Usually if you’re using bullets intended to be used with AR ammo, when the bullet cannelure is seated to the mouth of the case, OAL will be pretty close to where it needs to be. .005 or .010” one way or the other isn’t going to make any difference, as long as the case mouth is lined up with the cannelure, for a good consistent crimp.
I wouldn’t worry too much about OAL being a bit shorter than the book calls for, unless it’s way short.
It’s good that you’re sorting the brass, though I’d never use range brass .... you never know how many times they’ve been reloaded, or what’s been done to it. I always used the once-fired Mil brass.
Also, the powder I used was Winchester 748. After trying several, it was the most accurate.
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