Originally Posted by barnesuser28
what is your trim to lenght? your brass could be too long and when you push the shoulder back that might be enough to make it fit.
I'll go +1 on that.
But, if your trim length does NOT exceed the length of fresh cases, then my guess is that your barrel likely has a chamber that is out of spec. But first you need to make sure that the headspace is minimal. This is especially important if you run hot loads. From the #'s that you provide, it looks like the growth of the fired cases, as compared to fresh ones, exceeds what it should, or at least could, be. If the case moves back in the chamber when it's fired, it will grow slightly in diameter (depending on how much taper it has), as well as in length, and that can only make it more difficult to get it properly re-sized.
Starting with the assumption that the chamber specs out OK, there is the possibility that the headspace gauge that you are using could be OOS. Try taking a batch of say, 50 new cases, and setting your HS for zero slack on the largest one out of the batch. Then load and shoot a few of them. If that brings the growth #'s down, and they fit into the chamber OK after re-sizing to match new brass size (4.319), then that was the problem.
If THAT didn't work, the only other possibility that I can come up with (assuming that the re-sizing die is OK), is that the chamber was over-cut, over-reamed, or something of that nature.
P.S. I didn't see that other post until just now. Looks like I spent too much time with the reply window open. He is taking the position that the re-sizing die is what probably is NOT OK. And in hindsight, he is probably right to suspect that as being more likely the problem, before putting the blame on something more drastic, like the chamber. And being that he has already run into that problem more than once before, it does sound like the way to go.