Color a case in sharpie and see where its getting rubbed off.
Take measurements, speculation is useless, measurements are the only thing that matters.
For measuring your head space we use datums to measure a consistent point on the case each time.
This hornady body holds adapters to measure the case shoulders.
This is a headpsace bushing that will actually touch the shoulders
And it looks like this in operation. This is measuring the length from a point on the shoulders to the case head.
You want your sized cases to be .002" shorter than your fired cases. If your once fired is longer than your chamber then youll have issues.
Next you want to do the same thing but instead of measuring the case you measure the bullet. The actual over all lengths of the bullets can vary a good bit, the bullet comparator is a much more consistent method.
Now, this could also be fired out of a machine gun with huge chambers, in addition to length being out of whack they could also be toolarge in the base of the case, measure the diameter of the brass .2" up from the base and get its diameter, compare that you factory bras or some that have been fired out of your gun, if its way bigger than thats the issue and youll need a small base die. The regular die may be enough for normal brass but spring back with the machine gun brass may be more than it can handle, a small base will size it more so that once sprung back its not too large again.
If youre going to be changing things change one thing at a time and measure so you know why. Dont size more and then seat deeper in the same step. Size and check, seat and check etc. One variable at a time.
Also, measure the neck diameter of a loaded round and see if its too thick for your chamber. Its possible and could be very bad if so, neck turning is the solution to that issue.
But in looking at your posts if the only difference is that you powdered it then something else is the difference. Measure between the dummy and the powdered, that should be the most obvious method. Empty volume inside the case cant effect its external dimensions obviously, if youre not compressed then thats clearly not the issue.