Kinda depends on how you're getting the .006" variation. If it's +/- .003" that isn't bad. If it's +/- .006", not so good. I'd have to look at the Berry's 185 gr. FP to remember it's profile, but you may see less OACL variation by loading a bit longer like 1.200". Find the point on the bullet shank where diameter drops below .452". That is likely where the ogive begins and probably how I would determine OACL for that bullet.
Don't see a mention of how you seat and crimp, and in truth, when plated, or cast lead bullets are .001" larger than the barrel's groove diameter, you don't need to crimp since you are already .001" greater in interference fit. If you know the avg thickness of your cases, or find it, then it's just a matter of multiplying the thickness X 2 and add bullet diameter to determine the case-mouth diameter in just removing the flare from the expander. However, a light taper crimp won't hurt as you're just turning the square edge slightly into the bullet.
If you use the LEE FCD and load over-size bullets that are softer, be aware that while LEE calls it a Factory Crimp Die, it's also a post sizing die and in some cases can reduce the bullet's diameter. More likely with softer lead, but when you're at the end of your handloading session, you can pull a bullet and measure the shank diameter to see if it has been reduced. Less of a problem with plated than cast. Another reason poly-coated lead are, and will continue to get more popular.
Don't see a mention of how you seat and crimp, and in truth, when plated, or cast lead bullets are .001" larger than the barrel's groove diameter, you don't need to crimp since you are already .001" greater in interference fit. If you know the avg thickness of your cases, or find it, then it's just a matter of multiplying the thickness X 2 and add bullet diameter to determine the case-mouth diameter in just removing the flare from the expander. However, a light taper crimp won't hurt as you're just turning the square edge slightly into the bullet.
If you use the LEE FCD and load over-size bullets that are softer, be aware that while LEE calls it a Factory Crimp Die, it's also a post sizing die and in some cases can reduce the bullet's diameter. More likely with softer lead, but when you're at the end of your handloading session, you can pull a bullet and measure the shank diameter to see if it has been reduced. Less of a problem with plated than cast. Another reason poly-coated lead are, and will continue to get more popular.