OK, here is the latest: Someone suggested that I take a commercial round apart and simply replace the mfg bullet with the "issue bullet".
I loaded the issue bullet with the same powder and OAL., I also obtained a few "Berry's RNHB" and "Rainer JHP" and loaded them as recommended. Here are the results:
pistol: Springfield XDS. I changed from the VP9, to see the affect of standard rifling on the situation, even though the barrel is shorter.
upper left: 10 rounds @ 7yds, Federal Champion 115gr 1.159 OAL (factory load).
Upper right: 10 rounds @ 7yds, Federal Champion case, powder and "issue bullet", 115 gr 1.159 OAL. flyers are me.
center: 10 rounds @ 7yds, reload case, accurate #2, 4.2gr, issue bullet, 115gr, 1.130 OAL Note some key holing but much better.
lower left: 5 rounds @ 7yds, reload case accurate #2, 4.2gr, Berry's RN, 115gr, 1.140 OAL. losing concentration, but no key holing..
lower right: 10 rounds @ 7yds, reload case, accurate #2, 4.2gr, Rainer JHP, 115gr, 1.10 OAL. no excuses here, rounds seem tight and right. variance is me.
So, my next action, is to contact the bullet mfg, to see what they have to say, more to come.
I checked on line to see if I could get "bullet lengths" from several mfg. nothing listed., I will contact them to try to get this information.
I also have a Chrony on the way. I hope to use it to confirm velocities, to see if my loads/pressures are correct (work in progress).
thanks again for all the input!