Hey troyboy,
You're on the right track with your ladder testing and then fine tuning your groups. As for the rest...
I then loaded 9 rounds each of 39.5, 40, 40.5, 41, 41.5, 42 to do some 100yd grouping to see where the sweet spot is. Out of all those rounds I shot at 100yds 1 group came in at 1/2 MOA and all the others would either be 3 shots spread out over a couple of inches or had 2 bullets touching and the third shot would go 2 - 3" from the others.
Half a grain of powder can make a huge difference in accuracy. It wouldn't be a surprise if (examples) 40gr shot 1/2 MOA and the same cartridge with 40.5gr shot 3 MOA.
If you do have a load that's shooting 1/2 MOA though you're obviously making some progress.
I have read that u have to nearly push these bullets into the lands for good accuracy. The COAL is 2.790 and they touch the lands at about 2.815. Is this a too big of a jump
As a general rule, yes; you want the bullet to be "just off the lands". A widely accepted rule of thumb is that 10 thousandths of an inch off the lands is ideal.
This can vary a little bit, but if you're 0.010" off the lands and your groups are terrible you've got issues other than seating depth and COAL.
COAL isn't the be all and end all either and plenty of rifles shoot very well without this. Example... 7mm-08 factory COAL is 2.8". For my Tikka I set the COAL to 2.820 because that's the longest cartridge the magazine will accept. Any longer and they wont fit, and I would have to hand feed ammo which I'm not going to do.
TBH I've never bothered measuring how far off the lands this actually is because it doesn't matter to me. From reading other comments on the rifle though I believe this is about 0.03" - 0.04" off the lands which some would say is much too far.
For all that though my rifle shoots under .4 MOA so you can't complain with that, especially for a hunting sporter.
...the projectile is the 95 grain Sierra Match King...
...that's the reason for the s**t groups or is it because my twist rate just wont stabilize these bullets?
In this particular instance I think twist an issue for you. According to the Sierra website
6MM .243 CALIBER (.243) 95 GR. HPBT MATCH bullets require a 1:9 twist.
If you actually are getting a 1/2 MOA out of one of these loads like you mentioned above though then you can ignore that...
On that subject, and as a bit of general advice... Personally I think doing 3 shots groups for load testing is a waste of time. It is too inconsistent to get a true result from the load.
Say you have load A which is accurate, and load B which is terrible and shoot a 3 shot group of each. Load A you could shoot two touching holes and get a flyer 2" away. Load B you could shoot a 2" group but have the 3rd bullet overlap one of the first two holes by fluke.
Both groups are identical and don't tell you anything about the true accuracy of the load. Like you experienced yourself, you "had 2 bullets touching and the third shot would go 2 - 3" from the others."
Add to that pulling shots or any number of shooter errors or influence and your not likely to make a tonne of progress. IMO you want to be doing at least 4 or ideally 5 shots groups to be testing loads thoroughly.
Having said that though if you've gotten to a 1/2 MOA group after your ladder testing it doesn't like like a total write off. If you've still got enough projectiles left I would focus on your 1/2 MOA load and wrap up like so...
Say 40gr is the 1/2 MOA load. Load up a few batches of cartridge with 39.8, 39.9, 40, 40.1 and 40.2 gr powder charges. 5 cartridges per batch for the reasons explained above.
Go to the range, take a rear bag, rest or whatever you're most stable on. Take your with each one and do the best 5 shots groups you can for each batch.
If they're all terrible, then that's the end of it... Time to drive a different bullet and confirm the required twist first. If they show some good results, whichever one of them shoots best is your load.
Take that load, then start tuning the seating depth. There might be some appreciable improvement gained with a different COAL, or not. There is no point fiddling with it though if the basic accuracy of the cartridge isn't proven.
Did I cover everything
Hopefully. Ask away if not.