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The Hodgdon data is for a Barnes TSX. That is a copper monolithic bullet which is longer and tougher than your average jacketed lead bullet of the same weight. This means it takes up more space...

No. I would not make that assumption.

Gonna disagree with Micky on this one. The manufacturer will provide a minimum length (that will probably shoot OK) and by adhering to that, you won't risk...

1. Yes, very normal. 40-50gr of powder being blown down a 6mm bore on a skinny "superlite" barrel... That's lots of heat and not a lot of steel to distribute it.

2. More importantly, what can you...