So, in reading your responses and getting further into this I bought a few things.
Bore Scope (
@JR1200W3 you'll be happy to know)
Hornady OAL Gauge
Caliper Comparator Kit
Some additional background, after I had built my rifle I bought 500 projectiles (Berger 105 hybrids) to not only use as testing but to use the remainder for the prairie dog trip. Not a great choice for prairie dogs by the way. Of those 500 I shot about 250 in testing and load development. At no point during the development did I feel any rounds entering into battery hard or did I have rounds sticking. The final loads were shooting at about 2980 fps with a SD of 5. I then bought another 300 rounds to make up the difference (I have 500 cases of Alpha) and loaded those to the same spec (32.5gn Varget / .010" off lands / .267 neck bushing / COAL: ~2.440).
Measurements I made are below. My comparator .240 tool head ID measures about .232" ID for reference. My dies have been seated in a dedicated XL750 tool head and my micrometer setting has been documented from the first load, everything is tight. I measured a sample of 5 of each category.
2 things stand out to me here.
Projectile Ogive length (stand alone)
-First, the differences in projectile lots seem pretty surprising. Could it be that if the ogive is over .010" different, that the profile could be off as well?
-Or is it just a OAL variation at the base?
-Is this normal?
Lengths before and after reseating
-The cartridges after I reseated them still stuck in the chamber. This time I assisted them back with a cleaning rod but they entered into battery hard and ejected hard. I lowered my seating micrometer another .005" and they no longer stuck. So it seems like the engagement distance is shrinking somehow since these same rounds were cycling fine before.
-Both before and after reseating I could shake the cartridges and hear the Varget moving around, so they were not compressed loads as I had originally thought.
-Something pushed these projectiles forward .010", whether that's due to the Varget expanding in the heat or something else it seems less plausible but still possible.
The next two topics really alarmed me...
For the OAL gauge I resized a case, chucked it up in a lathe, and drilled and tapped it for a 5-16x36. I also opened the case neck up so a projectile could glide through it without resistance. I cannot get this thing to be repeatably accurate. If I insert a round backed way off, seat the case firmly, and very lightly seat the bullet to resistance I get measurements from 1.705-1.715". If I do the same and jam the projectile into the lands firmly I get measurements in the 1.8110-1.825" range. The later makes more sense but its a pretty inconsistent range and with jamming it like that its not telling me actual contact.
I bore scoped prior to cleaning and post cleaning. The barrel cleaned up really well in the rifling, crown looks fine, chamber looks ok, but I have pretty nasty fire cracking right at the opening to the throat on the very edge. I don't see it protruding past the edge very far. Mind you I only have 400-500 rounds through this thing. Is this an indication that my loads are too hot? I've seen a lot of data for 26" Dashers with velocities between 2900-3000fps, I thought that was a normal expected range for Dasher, is that not the case?
Bore scope video link:
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Now I'm completely comfortable with the notion that I got the land jump measurement wrong and that I was likely closer to the lands than I originally thought. That being said, even if I was .002" off I didnt experience issues until my trip. Could it be possible that the fire cracking I'm seeing is actually closing the ID of the throat due to material expansion? Why do I feel like the crazy hair guy from Ancient Aliens?