Here is what I do concerning OAL with pistol ammo. I set up my dies to get the length in the reloading manual. Then as long as it fits the magazine and passes drop test, I go with it. I only use my calipers to check that nothing has changed as far as seating depth. +.005" in OAL is quite common and nothing to worry about.
I do the same. I only load two pistol calibers, .45 ACP and .38 SPl. I have an old RIA 1911 barrel I use for plunk testing .45, and just use the cylinder itself on the .38.
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