If I recall correctly, you are a Glock shooter. I shoot glocks and CZ's (or used to shoot CZ's) a lot. I had the same problem as you when reloading lead or coated bullets. The slight inconsistency of lead or coated bullet sizes used to give me fits when case gauging. The crimp would be off, the seating depth would be inconsistent, blah, blah, etc. Between the mixed brass and lead bullets, I could never get 100 out of 100 to case gauge. I could get 100 out of 100 to case gage with Montana Gold jacketed bullets, but of course they are more expensive.
I found that the ones that would not case gage would usually not chamber in my CZ's. But they would shoot all day in my Glocks. I have never had a bullet that failed the case gage fail in the Glock (approx. 200K loaded). Therefore, I NEVER case gage anything that is going in the Glock anymore. It would have to be an obvious problem (lip rolled over, bullet upside down, etc) for it to not shoot in the Glock. I saved my rejects until I got 100 and then tried them for "gross" accuracy - 25 yards on 6 inch steel. Got the same hit % that I get with cartridges that pass, so I don't care. I know you are a GM and therefore a much more accurate shooter than me, so maybe you can tell the difference. But I think you may be wasting your time worrying about it.