Since you have some time on your hands, take the Max OAL load that passed the barrel drop/spin test and feed from the magazine to verify Ideal OAL that will reliably feed/chamber for all of your pistols.
If I were you, I would also load some 6.4 gr and 6.6 gr test loads (say 10 each charge) to map accuracy trends with.
Quizcat said:
I don't know if the SWC's are more accurate ... or even if that's all been disproved as a myth from the past with respect to accuracy.
SWC bullets are favored by match shooters as they "cut" cleaner "larger" holes on targets than RN bullets that merely "push aside' the target paper/cardboard. Some matches will score only holes inside the lines and scorers will actually push on the target from the back. So often, what appeared to be "A" zone hits will get scored as "B" zone hits.
As to bullet accuracy, it depends on powder and charges used. I usually make a direct link between consistent chamber pressures leading to consistent muzzle velocities (with lower SD numbers) that will result in tighter shot groups. For lead bullets, the build up of chamber pressure starts with the bearing surface of the bullet (part of the bullet that rides the rifling) engaging the start of rifling.
If you compare the 170 SWC and 180 TCFP bullets in the picture above, you'll note that the bearing surface of the two bullets are comparable in length (like 45ACP 230 RN vs 200 SWC). For match shooting, this gives the reloader the benefit of a lighter bullet with the same bearing surface length that can produce lighter felt recoil with larger holes for improved scoring.
For slower burning powders (say slower burning than W231/HP-38/Unique), consistency of powder burn and chamber pressures are usually obtained near the max load data powder charges. If I am loading full-power loads with jacketed bullets (using verified once-fired cases), this is fine but most of my range/practice rounds are loaded using mixed headstamp cases with unknown reload history. To reduce pressure related case failure concerns (especially for high pressure 40S&W loads), I prefer to back down from near max load data and use mid-to-high range load data. But to maintain consistent chamber pressure build up that will produce consistent muzzle velocities (accuracy), I need to use faster burning powders. Mid-to-high range W231/HP-38 load data do this pretty well and do not overly bulge the 40S&W cases even in generous chambered barrels.
Not sure about your Taurus PT140, but my PT145 has generous chamber compared to M&P45/Sig 1911 and has fed SWC loads smooth like butter. If I had to choose between SWC vs TCFP for match shooting, it would be SWC bullet.
BTW, Z Cast Bulletz does make 14-16 BHN180 gr RNFP bullet for 40S&W and I am waiting for an assortment of bullets to be shipped. I can post my range report of the bullets or send you a sample of the bullets along with a sample of all of Missouri 40 S&W bullets.