What are the dimensions of the plug you have vs what you need? Can't be too hard to knock one out on the lathe?
As far as the variation in pills, if you have a set of digital powder scales pick one of each pill and weigh them. If there is difference in weight between the three lengths that would be more of a concern for me than the actual length and I'd be sorting into three weight batches. Then load and shoot...
If they all weigh the same, then I'd be checking two things, the cannelure groove is the same distance from the base on all of them and the second is the ogive measurement - likely if the weight and groove is the same the difference will be the nose profile most likely which would probably be due to the tooling having slight differences in profile. If it's the ogive measurement that is the only difference - I would be fairly confident to just bang them off as it would not make too much of a difference for a Hornet from my experience.
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