I have reloaded a lot of 9mm, 40S&W and 45ACP loads (about several hundred thousand) and size does matter in this case:
- 45ACP cases are much larger and easier to pickup from the floor/ground
- Larger case/surface area with similar thickness of brass takes less effort to resize (similar to bending a longer section of paper clip vs shorter section)
- Larger sized primers are easier to detect and pickup (especially those occasional loose spent primers)
- The larger bullet is definitely easier to handle
- The availability of 45ACP bullet types and load data far out pace that of 40S&W (it seems, with each passing year, there's less and less powder to use for 40S&W)
- I tend to stick with 1.125" OAL for mostly common TCFP nose profile of 40S&W but have much greater flexibility of 1.200"-1.275" OAL for 45ACP to "fine tune" the load and my pistol/barrel will feed/chamber this OAL range
- I have some accurate 40S&W loads, but they are not as accurate as 45ACP loads
- My range sessions often run over 300-500+ rounds and slower "thump" recoil of 45ACP is easier on the hand/wrist than the sharp "snap" of 40S&W
- Yup, after 300-500+ round range session, I gotta pick those darn spent cases