darchell: The difference in velocity from the estimated or tested velocity in Berger's test barrel, or those barrels used in the manuals by the bullet makers will almost certainly differ from your actual results. The plain and simple reason is that there are "fast" barrels, and "slow" barrels. Two barrels from the same maker of the same caliber, made on the same day will vary in terms of both velocity and accuracy. Don't fret, it's normal.
As for the dies, for years I also used RCBS like many others, but over time switched to Redding, especially favoring their Competition Seating Dies, which perfectly align the bullet in a sleeve all during the seating process, ensuring perfect axial alignment with the case. This step is critical to good accuracy. RCBS dies are good, don't get me wrong, it's just that most accuracy minded shooters migrate to Redding, both sizing and seating dies. For most shooting in a 204 bolt gun, only neck sizing is required, and in a factory barrel, there's no real need to go to bushing dies unless you neck turn, and that is also pretty much not needed in a factory barrel.
I should also add that Forester dies are very good, and some shooters seem perfectly content using Lee dies. Many stick to the dies they started out with, and if they're getting the accuracy they feel is acceptable, then those dies are perfectly acceptable...to them.
As for the difference in seating pressure required to seat your bullets, that is usually caused by neck thickness variations of the brass that comes to light after sizing. This will cause vertical stringing of your groups on target due to differences in neck tension holding the bullet in the case. More neck tension required will strike differently on the target than light neck tension. To cure that, you'll have to sort your brass by neck thickness using a neck or tubing micrometer. Some lots of brass are good in regard to thickness, some are abysmal in that regard. Lots from the same maker can vary. You may get one lot that only differs about .0015", then another that varies a whopping .002" variance. You just have to check and sort them in lots, then keep them separate to avoid variances in neck tension. The other alternative is to neck turn them all to one thickness, which is alot more work than most shooters want to undertake.
If you are getting half inch groups now, simple sorting of your brass using the dies you have on hand now should provide you with very good accuracy. Many shooters will never get a rifle into the half inch range; you're already there. Sort your brass by neck thickness, use the load that gives you the .5" groups, and you'll most likely find those groups will shrink even more. Good luck, let us know how it shakes out.
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