My question is, if the 3" give you more shot, more range and more muzzle velocity why would anyone ever shoot 2 3/4"?
Is it just a recoil thing?
Giarc, first off the 3 inch 12 gauge shell does not give you more velocity than a 2 3/4 inch one. Pressure limits for shotshells ensure that they are all about the same velocity. Steel shot can be pushed faster than lead, but comparing load for load they are all about equal. Even the .410 has the same velocities as 12 gauge. Check the on line reloading data tables from the various powder manufacturers and see for yourself.
Waterfowl hunting requires the use of non - toxic shot. The least expensive no tox load is steel shot. Steel is much less dense than lead, and requires more space to hold an equal weight of shot. In other words, 1 1/4 oz. of lead takes up less volume than 1 1/4 oz. of steel. For this reason the 3 inch shell is popular among waterfowlers, the steel loads for big geese just won't fit in a 2 3/4 inch shell.
For virtually all other purposes (upland game, clay targets of all descriptions, etc.) the 2 3/4 inch shell with lead shot is more than sufficient and is less expensive than a 3 inch shell. Shooting a ruffed grouse with a big 3 inch shell doesn't leave you a lot to eat. Many (most?) clay target ranges require the use of #7 1/2 shot or smaller, 1 1/8th oz. or less. You will not find a 3 inch shell with those specifications.
The effective range of a shotshell firing pellets (as opposed to a slug) is limited by pattern density more than any other factor. Number 6 lead shot is still going fast enough to kill birds at 80 yards, but the pattern is so spread out at that range that a hit is not guaranteed, even if your aim was correct. The pattern is a function of the barrels and choke as much as it is a function of the load. A 3 inch shell will give you better range than a 2 3/4 inch one only in so far as it gives you more pellets to fill in the pattern at a distance. This is somewhat mitigated by the fact that the 3 inch shell has longer shot strings and does not pattern as well (as a rule of thumb) as the 2 3/4 inch shells do. In other words the effective range of the 3 inch and 2 3/4 inch shells are very similar, especially with lead shot. With larger size steel shot, the 3 inch shell has an advantage simply because you can't put enough of it into a 2 3/4 inch shell. In fact, the 3 inch was considered insufficient by some, so the 3 1/2 inch 12 gauge load was developed, and given a higher service pressure load to drive the pellets to the same velocity as the shorter shells.
3 inch slugs carry more energy than the shorter variety. A 2 3/4 inch Brenneke will kill any big game on this continent though, and the increased energy of the big shell is often considered unnecessary.
Felt recoil is simply a function of gun weight vs. load. If the recoil is uncomfortable, get a heavier gun. For many people, shotgun shooting involves a lot of walking, and a heavier gun is undesirable. A light weight gun wants a lighter load to maintain a comfortable level of recoil. The 2 3/4 inch shells can be had in very light loads if so desired.
So, for reasons of cost, versatility and effectiveness the 2 3/4 inch shell remains very popular and will continue to be so for a while yet. For those that need non toxic shot the 3 inch and to a lesser extent the 3 1/2 inch shells fill the need. As you can see it is not just a case of recoil or cost or effectiveness. It is that the various loads are developed for various purposes and the length of the shell varies with the need. With a rifle, you choose various calibres. With the 12 gauge shotgun, you choose various loads.
Just my $0.02
Sharptail