I had a couple of 6.5 Grendels and there was about 7 thousandths difference between the headspace length on the two rifles. I didn't want to work my brass that hard, nor did I want to have two different loads of ammo around. So I contacted Harrison at AR15performance, and sent the rifles off to have the headspace made closer between the two rifles. The rifles came back with 1.5 thousandths difference between the two headspaces, and I can live with that. Both rifles shoot great, and my brass is living a long time. I quit counting when my reloads went over 6 for the cases. If I don't anneal the necks split, that that is no surprise, so I anneal.
Because the Grendel's neck dimension is 5 thousandths larger than the 264 LBC reamer that was used on my rifles, Harrison did tell me that there would be a few thousandths difference (smaller) at the end of the neck because both rifles had a Grendel chamber and throat. As far as I can see, the small difference doesn't effect anything negatively.
Apparently, there can be some very small differences between the sizes of the various barrel extensions, and by adding a larger one to one rifle and a smaller one onto the other, things came out great. I'm not sure if I really understood how he worked things out to even out the headspace, so forgive me if my attempt at explanation isn't very good.