what would you consider an acceptable deviation of gauge stick out between chambers? One thumbnail? One Sharpie mark? Closer?
Well, generally 1/10 inch of depth equals a thou of taper in my chambers so for myself, I like the gage engagement to be essentially equal between chambers. When I get a variance of say .050 in depth I can "assume" that there's at least a half-thou (5 tenths) difference....but definitely A DIFFERENCE..... but still, FOR ME the test comes in brass life and interchangeability, ie I only started gaging in an attempt to EXPLAIN poor sizing performance. I started the process over 20 years ago when I had three barrels chambered at the same time and they didn't act the same. One day I lined 'em up and thumbnailed an upside down case down the hole to find out that OOOOPS! they headspaced "within a thou" but weren't all the same diameter...
A precision ball would be better, but I don’t have any in an appropriate size.
I can't see any facility in using a ball, for anything gun-related. Ball mic -maybe??- for casenecks? ....but I'll ALWAYS measure over the bullet anyways because I trust neither math nor measures.... nor bullets nor pressure rings....so WHY do I care??? A properly mandreled cut will show imperfection just as accurately as my fumbley-fingers can mic, plus the inside of the neck is about as smooth and artifact-free as the surface of the moon, and "bridging" ...and thin spots....and smearing... and just WHY???
For ME... this is just my opinion.
The old "balls are better for gaging tapers" fallacy just doesn't work for me. I wasted several dollars and some time trying to make a ball work as a gage for setting cone clearance until finally I set down, drew it up on a sketch-pad and asked myself WHY??? Set your cone angle to anything NEAR 30* and ain't no way any conventional sharp-edged datum measurement can be wrong.... I've still got fitty-hunnerd dollars worth of inch-ish balls kicking about and got ZERO use for em... especially since a lot of my chambers are so big a ball just sets in the hole measuring the broke edge of the chamber mouth....
Only thing you'll gain from dropping a ball into a .010tpi hole is
a stuck ball.
BTW, to add..... I make my datum rods long enough to stick out and be held by my fingers, and I generally concern myself only with that magical ".200 line" on the case. I can't see any advantage to measuring 'way down at the half-way point. If you got wobble, or eccentricity, or uneven reamer pressure, or flex or are trying to crunk into an off-center throat or are off-center at the holder end it'll show up most at the back.
And anyways, that's where cases bust and where the klik occurs
F'rinstance I've got 9 different reamers in .270/.300/.325/.338 WSM all done with the same body, ie .559 @ .200 datum and .010tpi. So I have a 2" long pin at .559 diameter that tells me a lot when I stick it in the hole.