Have you measured the shoulders on fired vs unfired brass? That'll confirm or rule out headspace.
That said... any other pressure signs? Would expect to see other problems if excessive headspace was an issue.
Have you measured to see what kind of jump the bullets have to the rifling?
What brass are you using? Need to drop the powder charge on some mil stuff.
When did you last give the chamber a good clean? Ideally no oil or residue in there, and no carbon buildup.
What primers are you using? CCI's are a bit harder than most. Federal are soft as shit and flatten out very easily.
How flat are we talking here? If you're up at/above 60kpsi, expect a LR primer to really start pancaking. Have they still got any hint of rounded edges? Have you noticed them getting flatter as you worked up or has it been consistent? How easy do they pop out when you de-prime? Are the pockets expanding? Still tight enough to hold a fresh primer?
... Pictures?
Bookmarks