Hey there Trapper Jack ,
while reading your post I came up with a couple questions.
1 are your cases weighing +-20 new or fired?
are you still getting black out down deep by the head?
I had a batch of R-P cases (500) and the whole batch only varied 4 gns so your numbers seem excessive ,the volumes of the cases are dependant on the conctruction of the case wall thickness web thickness and such . for just shooting not much matters other than you use the right components . When you start shooting for accuracy that is when you will find with black powder that consistancy is the thing . 1/2 gn bullets, neck tension ,case weight ,primer selection,overall length ,seating depth, and many more variables.
to maintain a smooth release of your bullet your case necks should be as clean and shiny as possible.this also has a good side effect as it keeps your cases from separating in the chamber on you , Cleaning the cases til they are shiny inside all the way to the head is good as it maintains a consistant volume in the case and it gets the corrosive junk out of your cases.
All this said you should keep your cases segregated at least by manufacturer and in a minimum af 2-3 gns weight for consistant case charging. the internal capacities of winchester brass has always been larger than R-P brass by 2 or 3 gns wt.
a simple test is to take a known measure and fill it to the brim with 3 f or something similar and then dump it in a few different cases and see how the volumes vary. or weigh a smaller charge and pour it (the one charge) into different cases the same way each time and measure the height in the case hope this helps...............Dean