1858 asks me:
1. How the heck do you accurately lap the the sizing die and measure the internal neck dimension of the die as you're doing it?
Strip the die, then chuck it in a lathe headstock; make sure it turns fairly well on center. For my 30 caliber FL dies, I took a 1/4th inch wood dowel, cut a slot in its end, then wrapped a strip of 150 grit emery paper around it to make a tight fit in the die's neck. Turn on the lathe, run the lapping tool in and out. Clean out, then measure the die's neck diameter with a hole micrometer. Lap, clean, measure...until it's 2 to 3 thousandths smaller than loaded round neck diameter.
2. Would neck sizing using a Redding neck-sizing die (using 0.003" smaller bushing than the loaded round neck diameter) followed by bumping the shoulder back with a Redding body die accomplish the same thing that you're suggesting?
Close, but no banana in my opinion. I prefer full-length sizing dies lapped out as they hold the body-shoulder junction better in place and sized case necks from this set up are a bit straighter. I've tried a couple of expensive neck sizing dies that bumped the shoulder back; none produced the accuracy I want.
3. What should we be aiming for (no pun intended) in terms of accuracy??
You decide the furthest you want to miss your point of aim, then double it; that's the accuracy you want, all the time, not just once in a while.
I like 1/4th MOA at 100 yards, 1/3 MOA at 300, 1/2 MOA at 600, 2/3 MOA at 800 yards and 3/4ths MOA at 1000. Here's a link to a test target using ammo with cases sized this way I shot after getting a new barrel on one of my Palma rifles:
http://www.flickr.com/photos/12787226@N00/3394146444/in/set-72157616051794780/
Please don't show this to benchresters; they won't believe it, they'll call you and me bad names, and maybe even tell our Mommies on us!!!!!!
Sierra Bullets used virtually the same process in their plant in California. Their best 30 caliber Match Kings would shoot 10-shot test groups in the ones (under 2/10ths MOA) at their 100-yard test range. The last time I chatted with one of their techs at their Missouri plant, they still do this at their 200 yard range getting 1/4th MOA or better.