NOT SIZING FAR ENOUGH!

Cover your brass in blue layout dye or sharpie and run it into the die. It should provide a clear picture of where it is not being sized. Also use your micrometer to measure critical areas of the brass against the reamer diagram which your chamber was cut with.

Odds are the brass was fired I a wildcat or out of spec chamber.

Rarely is the problem not sizing the shoulder back far enough, but it's possible. Have you measured it against brass fired in your chamber? I'd wager these tips will reveal the issue.

If it is the die not bumping the shoulder back far enough, you may ruin the brass anyway. The tip to take down the shell holder is a good one, but I'd only do so if the brass was fired in your gun...and only to bump back 0.002" or so. Personally, I advocate for using the large flat of a sharpening stone rather than a belt sander.
 
This has been mulled over before but I am trying to load for a just built 280AI. As you can see in the pic my Redding type S full length sizer is only able to get that much of the case sized. Even used a .010 bump die trying to get far enough down the case so the brass will chamber. No joy! Short of turning the die down shorter which with my luck will just ruin the die I am out of answers. Any good thoughts ?View attachment 220853
Any updates or a esolution to this? It would be interesting to know what you found.
 
All my brass sizes like that! I have the same results with Lee dies in .243 and 7mm-08, then again in two rifles in .280 Rem using redding dies and Lee dies. I thought it was normal as I have been reloading for over a decade with no issues and great results. I use Nosler brass almost exclusively. A little norma and Hornady also... but have discarded most of the Hornady over time.
 
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