Once fired military 308 processing HELP

[bsumoba]

...won't make a difference to headspace if it is not adjusted right.

True...maybe we need to know the brand of barrel and whether or not the bolt was headspaced to it.

But, I had this same exact problem with my JP barrel. Rounds would not fit in the case gauge, which is reamed with the same reamer JP uses in their 308 barrels, and was sitting a little proud. No matter what I tried, I could not get the case to size down any more. I didn't even try to chamber a dummy round. I ran it through a small base die and everything was a-okay. Never had issues.

Maybe we could suggest that he put factory ammo through the case gauge and if it fits, then put it in his rifle. If he wants to be completely safe, then take the powder and/or primer and re-seat the bullet. If it closes and ejects, then it is a brass issue.

[milotrain]

All this could be fixed if you have a headspace gauge with actual measurement functions. The Hornady, RCBS mic, MO's Mic, or Whidden mic will help you set your dies up correctly. Not all dies are designed for the same thickness of shell holder, you may have to grind down the shell holder to actually knock the shoulder back on your brass far enough.