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Down in the very fast end of the burn rate spectrum, lots of evidence would say that charge rates can be dropped to barely get the bullet out of the barrel with no "detonation" danger.
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I'm not a scientist of the internal ballistics type, but nearly all the KB'ed pistols I have seen in person or on the 'net involved low density loads of very dense, fast powder ...... usually titegroup in a .40S&W.
Your wild velocity swings tend to make me think that there is wide swing in pressure ....... and powder is progressive, with regard to burn rate- the higher the pressure, the faster it burns ....... what you are seeing can't be good.
While you may save a few cents on powder, you are making poor ammo, and risk being penny wise and pound foolish if you damage your gun.