Once your load is developed and the plunk test routinely works on your loads, you should be able to gauge and go! For instance, I know that any round that gauges in my DAA or Hundo will work in my Glocks. With my developed rounds, the only OAL check is the gauge sitting on a flat table, and seeing no rounds sticking up on top of the gauge. OAL problems have never happened to me with an already developed round on my presses. Rounds that won't gauge have happened with CBC brass and 147s. I wouldn't think you would be routinely out of battery to get light strikes. Is your RSA okay? Light strikes could be a light competition FP spring, or a primer that wasn't fully seated, or perhaps a combination. Did the rounds fire on the second strike?