Re: Brass weight
Strictly speaking, weight variances don't necessarily have to come from places that directly affect case volume - small things like a little fatter rim, etc. may cause case 'A' to weigh more than case 'B', while the differences in volume may or may not line up.
That said, if you do a decent sized statistical test you'll see that there is indeed *some* correlation between case weight and MV... but not a huge amount. Enough to be considered statistically 'significant', but thats not necessarily the same thing as saying it matters a whole lot in the real world.
Most people end up doing weight sorting because its quick and relatively painless - compared to the alternative, which involves plugging the flash hole, weighing, filling w/ liquid in a consistent and tedious manner, weighing again, etc. to establish the volume of the container (case). Not, necessarily, because sorting by weight is the best method.
For most purposes, most of the time... if you set up a load using something like the OCW process linked to above, your load will probably be 'tolerant' enough to withstand a little bit of variation in the case weight. For long-range competition, compared to the time/money invested in other stuff, it's not that big of a deal to sort cases by weight, and then 'batch' them accordingly, and/or use the 'tails' of the bell curve for sighters, load development, etc. and use the main body for matches. Thats pretty much what I do - first 100 goes into box 'A', next hundred go into box 'B', etc. The boxes taken from the 'ends' still usually have well less than 1 gn difference throughout, and the ones in the middle considerably less. I try to use the 'heavy' cases for load development. Its a cheap mental safety blanket, if nothing else
I will say that I have had a couple batches of Winchester .308 brass that had as much as a six or seven grain spread over relatively few cases (couple hundred), as opposed to two, maybe three grains spread over a couple 900-1000 case 'batches' for Lapua. Hindsight being what it is, I really wish I'd taken those Winchester cases and tested to see what sort of difference in internal volume and/or MV resulted from that much variation in weight.