If I could retitle this thread, I would say. THE DEVIL IS IN THE DETAILS. I finished shooting all the reloads that prompted this post, began the process of resizing and decapping a few hundred rounds. I still had the nasty feeling that I may repeat some earlier mistake that may have led me to an incorrect diagnosis.
This time I carefully reset my sizing die to reach as much of the full length of the case as possible, in fact it is now set to where the old RCBS Rockchucker Press will just cam over at the end of the stroke.
Measuring as many points of the case OD as possible ,the largest OD I can find now measures .4735-.474. Hopefully this die adjustment will eliminate the problem. I think Kenny Lee nailed the problem early some of my cases were not getting resized. I always tell my kids "we learn from our mistakes" my oldest son always replies, "right dad but really smart people learn from other peoples mistakes". I think the boy may have taken after his mom.
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