I just ordered a pellet gage. Up to now, I've only washed, lubed and sorted pellets for weight. I've noticed in my shooting ( a springer ), as I hand load each pellet, some slip into the bore quite easy while others there's a definite resistance as I insert it fully. Now that's gotta be head and skirt size related.
Opinions are, head size DOES make a difference in accuracy, at least, consistent accuracy. When I get my gage, I'll go thru the different weight pellets I have sorted already and play with different head sizes for each weight to see what my gun shoots best. Only then will I try to order new tins of pellets at a specific head size. But if you watch the videos, even a tin labeled a specific head size will have variations that you'd need to go thru to weed out those that don't conform, if, you want to remain consistent with why you started checking head size in the first place.
This procedure, from what I read, seems to be the "rule of thumb". Trail and error.
Geez, I guess this means I'll be rolling pellets pretty soon too. You guys are making me anal in my old age.
I saw this neat tool on YT for "resizing" too large pellets, multiples at a time.