1 i just WEIGH ALL MY CHARGES, period- i don't take it for granted what anyone says-how i set up mine was to remove the indexer bar so it won't rotate, then take an empty casing with a dead primer still in it, charge the case , and WEIGH THE CHARGE- on a beam scale- then you KNOW what you're throwing-
as far as the variance goes, if your hopper's brass nuts are tight, i don't think there's much you can do- you don't want them too tight as that'll impede the charge bar and stress the hopper base
it's an option as to whether to go fixed disc or adjustable, and i just leave the adjustable in as sometimes i shoot lead, sometimes jacketed, and various bullet weights or sometimes change powders- ie if my supplier doesn't have 231( which is what i always use) then i can go to titegroup or whatever without having to take the measure apart,just do the weighing thing with the scale again and we're back in business
i just looked at my hopper adjustable charge bar( it's a lee charge bar) and there's less than a hair's width between them- ie my hopper is almost but not quite RIDING on the charge bar-also there's no washers or anything on my screws-just the straight screw and nut
if your's isn't like that pls post a pic so we can see if the wings have been left high or something-