I am using acc 5 and Lyman says 1.45 for all powders. Lee says 1.481 for my powder. If I use Lyman’s OAL, it crimps in the groove. If I use Lee, you can see what happens in the pic. Lyman’s specifies a particular 158g cast bullet and I have no idea if that’s what I have. Lee only says cast with no particulars about the bullet.
Actually, I meant that as a rhetorical question, not a direct one to you...
But... you bring up a good point...
The Lee OAL is based on the bullet they were testing... which was not specified. That's one of the reasons I really don't like the Lee book, and I rarely use it. For that matter Lyman's data is based on the bullet they were testing, but they usually have a picture of the bullet, so you can compare bullet profiles, and depending on the edition, they list bullets that are compatible with that data, or if it's a cast bullet... it's prolly one of theirs.
In reality, both Lee and Lyman are not setting the OAL based on the
powder, per se, but the
bullet they are using. Most non-plated bullets have a crimp groove or cannelure, that is the place 99.9% of the handloaders will seat to, and very likely where the testers seated to for their data testing. That 1.481" in the Lee manual is what they came up with using whatever bullet they happened to have, very likely seating to the crimp groove.
I mentioned before that the solution you found seems to work well enough, what I eluded to in my following comment... about not being afraid to look for another bullet... is because what you have is not the ideal solution. As was mentioned, some levers don't like Special-length rounds, some have to be tuned, some just don't like them, period. I would probably try to find a proper solution... that is, a bullet long enough in a .38SPC case to function properly, or... probably the better solution... using .357MAG brass. I understand that may not be the answer you want to hear.