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DBT,

Hopefully the gunsmith will find the answer for you . I have very limited experience with the model 77 . I had a very simliar problems to what your describing with a 338WM model 70 win . I did everything you have and well know your frustration . On the plus side I did learn alot from that gun. Here are a few things I found on that rifle. You don't mention what scope you have or if you have tried a known reliable scope.

1. Check your scope for parallax.

2. Try another scope know to be reliable.

3. I know your rifle has intregal scope bases so I'm not sure if you can even get adjustable base's but . Make sure you aren't using to much windage or elevation on your scope. Use rear adjustment screw on your base's to keep the scope windage adjustment centered or Burris signiture rings , if available for model 77 , with the shims for the elevation . Should be able to use them for windage too. ( with dual dovetail mounts my 338 required all but 1/4 turn the windage adj. to get on target at 100 yards. This is not good for accurate shooting.)

4. Check your handloads for runout they should be under .003 . (this has made a huge difference in my consistency).

5. Try pressure bedding it . This has worked well for me in some case's.

6. Make sure your action screws aren't to tight or that they are not bottoming out before the action is tight ( an ocasional problem on model 70's ). Hard to beleive but it does seem to make a difference.

7. Make sure your barrel is clean . ( I have a very accurate 300 wm that will just suddenly start throughing fliers . Clean the barrel and it's back shooting groups again .

8. As wierd as it sounds some guns don't like to be cleaned. My 300 and 338 Ultra mags. both seem to shoot much better with a fouled barrel.

9. If all else fails and you really like the gun try a new barrel . It sounds like you have alot of time and $$ into this. Some times it's time to cut and run . They make new ones every day. FWIW My model 70 has long since passed to another to have his go at it.

Good luck with your gun I know exactly how you feel. Good hunting KHH

OK, it took a while, but the shop finally got around to checking out my Ruger - they got much the same results as I did.
They tried a different scope as well, and the results were still in its usual range of inconsistency.
It finally just came down to a barrel that shoots to "hunting level"

I thought about cutting my losses, but seeing I've come this far with the damn thing, I decided to rebarrel it.

A really fancy bit of work too - a custom MAB, medium contour, fluted stainless in 7-08 Ackley. Whoo hoo!

I can only hope that it shoots this time.

Well I've got the rifle, it looks good...but I can't shoot it, as the 7mm neck resisizer has not arrived - apparently the supplier has none in stock and it has to come in the next shipment from the US.
None of the gunshops in town stock factory loads either, the minimum order is for 200 rounds for $380.
Bloody hell it could be a long wait to see how the new baby performs.