I already ran this by Kevin Cramm at Montour County Rifles who chambered and fitted the barrel along with straightening the action and he suggested I lay it on you guys as he doesn’t have much experience with 25-06AI. The action is a Weatherby/Howa long action and a new .257 Rock barrel. I fire formed my brass with factory Winchester 120 grain loads. I noticed what appeared to be a slight bulge on every case just above the head. I used Winchester because I don’t have a very high opinion of Remington brass. I prepped the brass and loaded eight different loads differing by 0.2 grains for a total of 16 as described in a previous thread. 110 gr. Accubond 10 thousands off the lands with a starting load of 62.6 to 63.8 grains of H-1000. I found a good load of 63.6 grains as a base for further testing with no apparent signs of pressure . I showed them to a friend to see what he thought. He immediately noticed the bulging and after examining all the cases we discovered one that was cracked right at the bulge about ½ way around. This was not the highest load tested, I know because I had them labeled with the load. It was the 63.4 grain load. That case had to be very near total head separation. I cleaned and annealed the cases I shot minus the cracked one. I haven’t resized yet as I think these might be toast. I’m going to try to get a couple of different factory loads with other than Winchester brass to see if the effect is the same. From reading on another thread it sounds as though there might be a problem with the chamber itself or the bolt being off center of the chamber since the initial bulging happened with the factory loads. I don’t know the procedure used for chambering the barrel or whether go-no go gauges were used. Maybe Kevin will add that information. Again, I ran this by Kevin first as not to appear to be hanging him out on a forum before discussing this with him and he suggested I get the collective board’s opinion. I will try to post a picture of the brass. If there is any other information I can provide let me know.