How often do you measure the CBTO after seating bullet?
I measure every one. I measure them using Mitutoyo calipers with a Sinclair comparator tool, except that it has the Hornady inserts (slightly smaller hole). I'm using a Rockchucker press and Redding Type S Match dies, so nothing fancy. I usually do not see more than +/- .0005" seating depth variation with Berger straight bullets out of the box. However, if one ever does come up a couple thousandths or so long, dial down the seating die micrometer appropriately and seat it again. If one comes up more than .0015" or so short, it becomes a sighter/fouler round. Until recently, I did not sort bullets in any way...just loaded them up straight from the box.
However, I have been playing with meplat trimming/bullet pointing recently. I found that I needed a different pointing die insert to get optimal results from trimmed meplats. With the one I had, trimmed meplats looked worse after pointing than they did before trimming. While waiting for the new pointing die insert, I decided to point a few straight out of the box. Once the die was set correctly, they looked great and performed even better. As a result, I started measuring bullets and determined the OAL variation to be about .012"-0.15", for several different types of Berger Target bullets. IMO, this is pretty typical variance. Anyhow, the important point is that if you're not trimming bullets to equal length before pointing them, you have to length sort bullets and adjust the pointing die micrometer appropriately or else shorter bullets will be pointed correctly and the longer ones will have a bulge behind the meplat, or else the longer bullets will be pointed correctly and the shorter ones not pointed enough (or at all). Frankly, I find length sorting bullets much easier and faster than trimming, so that's what I've been doing.
How do you measure ogive radius?
I don't sort by ogive, although I know quite a few F-Class shooters that do. Most that I know personally prefer the tool from Bob Green:
Bob Green New Products
Also, when does bullet weight variation come into play? Do you not have to pay attention to it because the CBTO is that important?
During my bullet pointing/length sorting adventures I described above, I found that sorting several boxes of bullets into 4 groups that varied by ~.003" per group allowed me to reset the pointing die mic by .003" for each group, and that this was a sufficiently small increment that the pointing die could do its job correctly. On a whim, I decided to weigh a bunch of bullets from each length group on my analytical balance, thinking that the longer groups would average slightly heavier. That turned out to be wrong. Just to briefly summarize, the avg weights in all 4 length groups varied less than 0.1%, whereas length variation was slightly over 1.0%, or more than ten-fold higher. To be fair, this was for a few boxes from a single lot of Berger bullets, so other lots and/or manufacturers may be quite different. But the take home message is that I don't sort bullets by weight. Nor do I sort brass cases by weight; it has been demonstrated by many people that case weight does not correlate with volume in a statistically meaningful way. If you want to sort cases by volume, then sort them by volume.
When you begin rolling your own, I think if you do the following, you will be happy with the results:
1) start with high quality virgin brass and bullets from a reputable manufacturer
2) choose a powder that is appropriate for your rifle/bullet/purpose, and weigh it as accurately/precisely as it is possible for you to do
3) become familiar with your equipment so that your neck tension and seating depths are as consistent as possible, with minimal runout
Just make sure you get the basics down first, then it becomes much easier to add various sorting and other fine tuning steps to your routine later. Early on, they can interfere with the learning process. I would also strongly recommend that you follow Dan Newberry's OCW process for load development to start. Follow it exactly, without skipping any steps. It definitely works and will help you get a better feel for things like CBTO, COAL, etc., and how they fit into the grand scheme of things.