Three pages in, and nobody has mentioned switching to low pressure steels? :-D
I never get a short fill on an LP tank.
I bought some LP 85s some years ago, intending to use them primarily for sidemount, but I also used them for single tank diving. I go to Florida for a couple of months every winter, and the fill shop I had used for years routinely filled them to 3,000 PSI, giving me a fill of about 100 cubic feet. Then that shop closed, and I got the tanks filled by the operator of the boat I usually used for my dives. I got a short fill--about 2400. I asked about it, and they said 2400 was their rated pressure. I explained about the + rating, and I got it filled
almost to that. That became the standard experience--not quite the 2640 + rating.
Then some friends came to dive with me, and they rented AL 80s from the shop. They were filled to 3300-3400 every time. The shop apparently felt it was good to overfill the AL 80s to make the customer happy, but they felt it was too dangerous to fill LP tanks all the way to their rated pressures. I found it ironic that I got less gas in my LP 85s than my friends got in their AL 80s. (One of the employees would fill the tanks to whatever I wanted, but he was the exception.) I stayed with the shop because it was really convenient to just leave my tanks there and then pick them up when i was ready to dive.
I asked an employee why they are willing to overfill AL tanks but not steel tanks, and he did not have an answer. I talked to the manager after a fill to 2500 (the manager had filled it), and he said it was a matter of safety--he could not put employees at risk filling LP tanks beyond their rated pressure. I asked if he could at least fill them
TO their rated pressure, and he said I was "just splitting hairs."
That was last year. This year I found a different shop, and I get my LP tanks filled there. I get great fills there, and I will continue to go there for my fills, even though the location makes it inconvenient. It pays to shop around.