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Sorry, I really don't understand what you are asking.

This has me stumped also.
"I set up a few rifles with improvements, back than I did it the old hard way."

I would like to help but need a bit more info to go on.

Check this link:

http://www.hornady.com/story.php?s=485

I have and use the Stoney Point gauges (now sold by Hornady) and they do everything I want. I've got both the headspace gauges and the over-all length setup. Use them with your dial caliper and it gives more accurate measurements of smaller increments than 1/32 of an inch.

I have a bolt action rifle that I'm going to try to find the most accurate setting of OAL on my next range trip and here's what I'm doing. This may or may not work for you.
I have already tested the rifle with increasing powder charges and found 48 grains (IIRC) is a good accurate medium range load with the powder I'm using and the bullet .020" off the rifling. I'm only interested in accuracy at 100 yards with this one so velocity does not matter right now. I loaded 100 rounds with 48 grain charges and the bullet seated longer than into-the-rifling. I already measured how long a round seated into the rifling will be. On my next range trip I'll bring along my little Lee reloader press and C clamp it to the bench and have my Forster Ultra Micrometer seater die in it. I'll set it to seat 3 or 5 bullets into the rifling and test them, then I'll seat 3 or 5 more .005" shorter and try them on a different target. I'll do this to about .030" off the rifling and then see what I've got and if any group has potential. If so, I'll go back to that setting and try to vary the seating about .002" plus or minus to see if there is a difference then pick the best setting and try 2 ten shot groups to see what it does. If that works out, I'll fire whatever is left over at that setting in 10 shot groups for practice. Then it's reload the cases and I'm ready for our military rifle matches this summer!
I use 10 shot groups to prove the load because I think it really shows how the load performs much better than 3 or 5 shot groups. It's easier to see the center of the group not the measured center of the group and if any shots were uncalled flyers. We shoot 10 shot groups in our matches and until then I never realized how easy it is to be fooled by the 3 and 5 shot groups as to how the rifle will perform during the match.
I have read that the pressure will sometimes increase with the bullets seated closer to the rifling and that's why I'm using a mid range load. If I were at a top end load I would back off the powder first and work up again after the length is set. Believe me I'll be watching for pressure signs.
Hope there's something in here that is helpful.