It sounds like you have everything setup correctly. What powder and charge weight are you running? Also have you checked length after seating then again after crimp to see if the crimp station is causing an issue? Check lengths after each station. Another thing is you said you are hand seating, this could be another variable. Even though I don't use a bullet feeder I still use the feeding die and handload into the top of the die. That has helped my consistency as well.
All mixed head stamps won't give me that kind of OAL variance you describe. The only time I ran into an issue like that was a slow lot of SWMP I had to fill cases so full some loads wouldn't compress well and OAL changed wildly like that. Outside of that all load to +/-.003
EGW HD Doesn't really require much tension to run. I would set it up on the looser end where it just takes a few shakes to rattle a round out. Take it to the range and shoot it for function. Single load a round and drop a mag. Fire a round and see if it ejects normally while unsuported by having a round below it. If it does, that's usually enough extractor tension.
Your story isn't really adding up. A gun .0005 -.001 "out of battery" would still fire. Also that much wouldn't require a push into battery let alone be noticeable enough to cause any further attention. If you are having to push it into battery its got to be .050 to .100 from chambering, which could be a number of issues.
I currently have an egw hammer and a harrison true radius sear. I run a 15lb hammer spring. Trigger comes in at 1lb 13oz. Took a lot of sear spring tuning to get everything set right and reliable but the combo works great.
As above either extend the decap pin or you are getting primer pull back. I Chucked my decap pin in a drill, sanded with 1200 grit and then scotch brite to polish, after I did this no more issues.
I like a quick return and flat, I'm looking at minimal dot movement rather than how it "feels" in the hand. Current setup is a 5.4 barrel 2x 3/16 popple with 2 port Binary comp. Load is 9.9 gr of AA7 at 1.165 using a 7lb recoil and 15lb mainspring. Gun is very flat in video and returns quick.
It's a fairly minor hole really. The argument that it gives 9mm hicap no place to play is kind of lame. The people that are doing that anyway typically aren't heavily invested into being a regular of the sport. It's typically newbs showing up to give it a go for the first time with what they have.
USPSA needs to cut divisions and do something to seperate what we have now.
Open as is
Lim as is
PCC as is
CO/LO combine and make 15 rounds
Locap = SS, Prod Revo, L10 10 round Minor 8 round Major
Run 3 Nationals a year. Open/PCC/Lim
CO/LO
LoCap
I don't know of any. I just don't think they are nearly as popular as other makes because the mags already drop free easily especially from steel grip like are so prevelant now.