There are too many variables that lead to inconsistent results. One major one is that this method depends on the temper (hardness) of the brass. This variable changes between case manufacturers, manufacturing lots, how many times the case has been fired, etc
Very true - which is why you can only base expansion readings off exact components. If any components are changed, you have to start from scratch. One should keep in mind that case head expansion by itself is just that. Like primer appearance by itself is just primer appearance. That brass hardness variable can be applied to every single component we use for our handloads. Aren't we all careful even with a different lot of powder? I am - never had a reason to be, but I still am. Pressure signs will always be open for debate by themselves, but used together they will tell the truth.
I use primer appearance(by this I mean metal appearance under a magnifying glass -not flattened primers), case head expansion, felt recoil, and velocity as indicators as to where I am in regards to pressure in my handloads. When one sign shows up, I'll start watching for another, when I have 2 out of 4 I stop. My experience with Project 41(using published loads) educated me. I've just recently added head expansion to the list, and I won't stop watching it.
T/C nimrod you probably named the best way but I'm loading for the 300 whisper. I guess I could break down and order a box from Corbon as for as I know they are the only factory load.
I had the same question about my wildcats. My theory (and for GB's sake I stress it's a theory - not a sound fact) is that published starting loads will give me a good baseline to work with. I proceed alot slower and with more reserve when working this way. Bottom line is case head expansion will (and always has the little amount of time I've worked with it) have a "plateau". When you begin expanding cases past this plateau it's time to back down.
I've been doing a lot of pressure research over the last few months to try and get a true understanding of it's dynamics. There is nothing cut in stone - too many variables. Just my ideas and experiences and what can be deduced from them. This topic is a can of worms, but not a big one - there aren't enough consistencies to make it an arguementative point.