The styrafoam sounds like a good idea for loads in a straight case requiring a filler. I'd be cautious about using it in a bottle necked case but then I guess you couldn't use the cookie cutter method for a neat plug anyway.
I'm a little surprised you have to use a filler with this particular load though. You didn't say if you were loading 38 Specials or 38 S&W but 5.7 grains of Unique in either one ought to ignite without having to use a filler. I've used 10.6 grains of Unique in the 44 Magnum for a midrange load for years and never had an ignition failure. I've used it for a midrange load in the 357 Magnum also, although I can't recall the exact charge.
The one place I did have an ignition failure was with about 43 grains of a slow rifle powder in the 400-360. The primer drove the bullet about eight inches up the barrel. That would be ugly if you fired a good round behind it. You have to watch for this sort of thing.
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