Thanks. The funny thing is I have just finished 1000+ rounds of .45 as well. I had some Speer 230gr FMJ bullets and loaded to a COL of 1.265" but I didn't notice the difference with the Berrys 230gr bullets and kept it at 1.265"!!!!
I'm not too worried but I might adjust my next batch of Berrys.
It probably doesn't matter much either way. For most cartridges (unless you're really trying to push the envelope) there's enough of a safety factor to allow for minor variations in bullet shape and length without putting you in danger.
For example, on hand right now I have 4 different 180 gr RNFP FMJ .40 caliber bullets from 4 different manufacturers for loading 10mm. These bullets have slightly different lengths and shapes. When I load them, I'll do my best to keep the volume
under the bullet the same when I change bullet types. As a result, I'll end up with different a C.O.A.L. for each bullet.
If I find that one or more of my guns has a length induced reliability problem, then I'll cross that particular bullet and load off of my list. Fortunately, I own revolvers in most of my auto calibers so these bullets seldom go to waste.
There are some calibers, like the .40 S&W where you need to be more careful with the case volume. I don't own a .40 S&W, but if I did and if I loaded for it, I'd be very careful about the C.O.A.L. I'd probably end up having to buy bullets retail instead of the usual eBay-bullet-of-the-month club.
The one caliber where I've started to push the envelope is the .460 S&W Magnum. For this, I use the exact bullet (weight,shape, and manufacturer's model number) indicated in the load data, and I load to the exact C.O.A.L. recommended.
In this case, the bullet itself is pretty important. Because they both use .452" diameter bullets, it is possible to load a jacketed bullet meant for the .45 LC into a .460 case. The problem is that a bullet intended for a .45 Colt might disintegrate when you try to drive it up over 2000 fps, and that would be bad.