Good to hear you found the problem. Even with the flex you had, I would have never thought the shell plate/die relationship would have been that much out of spec to change OAL. Interesting lesson learned and thanks for sharing
I like the die set. The resize die sizes deeper and tighter than any other 9mm die I've tried. Seating die is very forgiving with bullet placement. Crimp die is just a crimp die.
Id hope so. +/- 1/2 thou is stupid precise.
I've certainly heard/believed inconsistent stroke or mushy mount/bench could cause some variation, but I admit to being surprised it caused THAT much variation. Glad it's all straightened out!