Now that' s not fair. You' re not supposed to ask me more questions than I asked you!!!

We size down to the belt, but stop short of the belt by .0001" . Yes we use a full stroke down to the plate. The dies are Hornady. Yes, we shoot the factory ammo, then reload the brass, both with Hornady and the others. It does it in two different rifles. One is a Browning M1000 Eclipse, the other is a Browning White Gold Medallion. My buddy forgot to lube a case one time and got it stuck, then ruined the die trying to get it out, Hornady sent a new die, but the problem still exists. We kept the brass from our rifles seperate, but I don' t see what that has to do with anything if we' re full length resizing. We haven' t measured the diameter behind the belt. And no obstructions on the bolt faces. We both keep them clean. And, I' m sure we' re not setting the bullet too far out as empty, resized, cases won' t work either. I don' t have a shoulder angle measuring tool, but when we eyeball the case that won' t work, with the cases that will, there' s no visible difference that we can tell such as lengthening the shoulder.

Did I answer everything? Now you see why we' re kind of frustrated. [:@]
I noticed that the Federal brass seems a little more stout (maybe thicker or different grade of brass) than all the others.

Thanks for the help guys.