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WPCexpert,
Don't worry about the 0.001" diameter difference between Hornady and other manufacturers.
On the other hand, there can be other differences in bullet construction that do make a difference in pressure for bullets of the same weight. These include where the cannelure is located on the bullet (how much space INSIDE the case is filled by the bullet), how hard the lead alloy is in the bullet's core, how thick the jacket is, etc. etc.
So, it is best to use data for a specific bullet when handloading, rather than just substitute one for the other in a recipe.
But, in reality, there is often no data for the bullet you want with the powder you want. So, substitutions are often made.
When substituting, you should go down to the start load and carefully work-up from there. This should keep you safe enough in a strong gun, such as the ones designed for the .44 mag. But, for old guns designed for low-pressure cartridges like the .45 Long Colt, substitutions can get you into trouble before there are any pressure signs when working-up the load. So, sticking to pressure-tested data for weak guns is a good idea.
SL1
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