wileynet…
I shoot the same handgun and I have my reloads using the 45-270-SAA seated to an OCL of 1.628” and there is still room on the chamber of the cylinder to seat it a bit longer…
So, your OCL is not too long…
I seat and crimp in one step, at least for all of my straight-walled handgun cases. No reason you can’t at all…
Screw your seating die out so that with a case in it full up position, the case mouth is not touched by the crimp ring in the seating die…
Unscrew the seating stem so that when you have the case and boolit in the full up posting on the die, it is not touching the boolit…
Slowly screw the seating stem down until it touches the boolit. Continue to seat the boolit a bit each time by screwing the seating stem in. Do this until you get the boolit to the depth you want it seated…
Back the seating stem out and with the cartridge still in the up position in the die; screw the die down until you feel the crimp ring touch the case mouth. Lower the case a bit from the die and screw the die down a bit. You raise the case again and you will begin to fell the crimp start. Do this until you get a minimal crimp—just to remove the bell or a bit more. Doesn’t take much more than that…
Lock the die in place with the lock ring. Then with the cartridge in the full up position in the die, screw the seating stem down until it touches the boolit. Lock it in place…
You know have a seating die set to seat the boolit and crimp lightly with one step…
This should solve your problem…
One other thing will cause what you are mentioning—a primer that is not seated below flush with the base of the case…
Crimping dies are O.K. as a matter of fact, I have many. But for general shooting and plinking with a handgun, they are not necessary if the seating/crimping is done correctly…
They are just and extra expense...
Good-luck…BCB