100% case fill means full of powder _without compression_, it doesn't mean filling the case to the top and seating the bullet, that is well over 100% case fill, and can still be good (110% case fill would indicate 10% compression of the powder volume). I have found that compressed loads can often give better consistency of burn so I consider "compressed to be good". My .204 load I actually fill to overflow (30gn of AR2206H), then hold the bullet on top of the pile of powder, and seat it. I haven't measured the percentage of compression with this load but it shoots extremely well with zero pressure signs. If I could fit more powder in there I would've continued load development as it just grouped better and better as I increased the charge, and I'm still well short of pressure signs.
In my milsurps I almost always use AR2206H, definitely not a slow rifle powder. In a few milsurp loads I use other powders like BM8208, AR2208 and AR2209, but mostly by far AR2206H, a fast rifle powder.
100% case fill doesn't automatically give more recoil, or burn the throat out, it depends on the density of the powder, which you clearly understand from your point 6. For example, a full case of Trailboss in the 7mm-08 is probably only 15gn, but I can fit 52.1gn of AR2206H in the same case. If I used W748 I could probably get 60-70gn of powder in there, which would be disastrous. With a long bullet that seats well below the neck I can be happy to see powder up to the neck as it gives good compression, with shorter bullets that barely seat below the neck I like to see the powder inside the neck to give some compression. I do agree that you are likely to get more throat wear burning larger charges of powder, another reason I prefer AR2206 generally.
I definitely agree about not chasing velocity, especially in milsurps. I don't even want to run them at the pressures they used to run at when they were in service. My "target" is to load to 90% of the muzzle energy of the original load, this gives more than enough recoil to get the "feel" of shooting full-power loads without working the rifle hard. My .303 load of 38gn of AR2206H behind 174gn jacketed bullets at 3.050" is technically ADI's listed maximum load, but gives me that 90% energy figure with excellent case life and zero pressure signs.
I can't comment on the M1 Rifle specifically, but my neighbour shoots a Remington 700 ADL and wanted to be able to reload to the same performance as the factory .30-06 he'd been using for deer. Ideally I would've wanted to chrono his factory load in my rifle to duplicate it but we couldn't get any, that's why he wanted to reload. I don't recall what the ammo was but it was a 180gn soft-point bullet at 2700fps - from memory he told me the ammo and I chased up the spec, I doubt he had ever chronoed it. So I "worked up" a load for my M1903-A3 of 56gn of AR2209 at 3.258", which gave me an average of 2701fps. He brought his rifle around and tried it and was very happy with the result, though it only made 2582fps in his rifle. These loads are certainly "stout" and if I were going to shoot them a lot I'd work them up with AR2206H instead as they'd only use around 46gn of powder. His ADL was also 116fps slower than mine with my Berry's Copper-Plated 150gn 1750fps load.
Now, when I say "I worked up a load" for it, I had previously (seven days after I got the rifle) loaded ten rounds with the 178gn BTSP on 57gn of AR2209 at 3.385", again the only load I tested with the bullet, and it shot very well, so that is basically my "precision" load for this rifle - I didn't bother with any further development of it. It was in 2018 and I probably wrote the details on the target and photographed it as I didn't record the velocity or group sizes in the logbook, and don't have access to those photos now. To settle so quickly I would assume it grouped very well for me. Now, "working up a load" for my mate's rifle consisted simply of analysing a variety of data and calculating that 56gn of AR2209 should get me close to 2700fps, so I loaded ten rounds. I fired the ten rounds for a group over the chronograph in my M1903-A3 and it gave me an average of 2701fps and a 50m 42mm group (open sights off a bag). ES was high at 71fps (2566fps to 2737fps, but the highest and lowest were slightly anomalous, the middle eight rounds only had an ES of 42fps so I felt the load was just fine for deer shooting (my mate couldn't recall ever shooting a deer further than 100m). I also didn't record his (scoped) group sizes in the log, only his velocities, but it was no worse than the factory ammo he'd been using for years, so we did no further development of the load.
For competition shooting, unless you are knocking down big lumps of steel, you don't need velocity to ring gongs or punch paper. Velocity can be useful for beating wind, but a couple hundred fps makes very little difference. The 168gn ELDM for example at 1000m in a 10mph wind has about 2700mm drift at 2750fps and 3000mm drift at 2550fps. I can't see that small a difference causing a win.
One-minute at 300yd is 80mm, so 3MoA is a 240mm group.
Vince24 wrote:in2anity wrote:A old timer once said to me; "I've figured out the secret formula to all my rifles. It's... <DRUMROLL> ... 100% case fill".
It's worked for me, to this day, in all my rifles, ranging from my service rifles, through to sporters, through to my target rifles.
Any service rifle should be grouping into 3moa at worst at 300m, preferably 2moa, otherwise you are just wasting your time.
In2anity, you can't be serious.
I am sure that your science of load development for military rifles goes beyond the simple act of stuffing a case with powder till it overflows.
1) get a 100% case fill - without blowing up your brain

- in most old military calibres (other than 308W) means using a huge quantity of a very slow powder.
2) It is well known by now that this is the recipe for accelerated barrel wear (and probably the rest of the rifle too). If we are talking about a service rifle lucky enough to still have its original barrel, this is almost a crime

- it is our duty to preserve those old weapons for the future, so let's keep the hot loads for the Howa/Tikka and the like.
3) A 100% case fill is also going to generate heavy recoil - which is going to make most shooters shoot less well. And honestly don't tell me you enjoy shooting a lightweight 1903 stuffed with 62 grains of 2209. While that rifle can be a pleasure to shoot with e.g. 48 grains of 2206H behind the same 150 grain projectile - and still very accurate.
4) I don't even talk about the longevity of your cases - I guess that 's a choice
5) From my experience of doing load developments, I haven't noticed that the hottest loads were always the best. Sometimes yes, sometimes no. And sometimes the hottest load can be just barely better than a much milder load, not making it worth the pain for military shoots.
6) Military competitions are shot with no rest in various positions - I think working on your shooting technique will yield more results that punishing yourself with 48 grains of 2209 behind your SMK in your SMLE when 40 grains of 2208 may do the same job,in a much more enjoyable manner.
7) France have a very competitive and regulated national competion for military style rifles. Sometimes a (suspiciously well prepared lol

) M1 Garand make it to a podium - I can guarantee that that Garand does not run on a 60 grain load because an M1 can't handle this. Granted it's only shot at 200m but what groups at 200m will group at 300 yards.
By the way, 3 MOA at 300 yards, isn't it like a 25cm circle?
I am new to military comps and I wouldn't say it's easy to group 10 shots in that circle with military sights from the prone position, but recently I have grouped 7 out of 10 in that circle (and a case not filled at all!) with the 3 outside of the group being clearly shooter mistakes. I am working on this and hopefully I can improve (need to get a good sling

), still without putting 60 grains in my 30-06 round!
