Hornady brass, correct? If you're expanding the sidewalls out, it's just an itsy bitsy, teeny weenie more understandable. But it still indicates **** for brass, IMO. Should be no problems expanding / fire forming those sidewalls out to the slightly larger diameter. I'd send the rest back to Hornady for a refund. Not a replacement with more reject casings. And I'd tell them their brass sucks big-time.