So after checking all of the above I dug around in the reloading room and started checking other sized brass with the Hornady Comparator and chambering them. I should have done this sooner but I'm slow sometimes. Remington, Federal, and LC sized cases mostly all measured 1.462 and those chambered and ejected just fine. I found a few as high as 1.464 and those were getting pretty sticky. I found one LC that was 1.465 and that one requred both hands on the charging handle. They are nice and clean so if they were all dirty like rounds get in the magazine when shooting a suppressor they would have been worse I'm sure.
So it looks like I need to get to 1.462 for smooth extraction and for whatever reason that is not very reliable with my old Winchester brass, which is a bummer because I have probably 700+ pieces of Win all trimmed up and no primer crimps.
I also don't understand why I am getting so much variation in headspace on sized brass, even in the same headstamp. Across all headstamps I'm getting as much as .01 variance. I am using a cheapo Lee Challenger press and should invest in something better but I don't know that it is causing the problem. I generally get sub MOA accuracy, but that may explain some fliers.
Thanks for the help. Now I know what the problem is I'm just not sure how to fix the occasional inconsistencies I'm getting with brass other than Winchester. And I don't know what to do with the Winchester at all? I feel like I need to just start over and buy new dies and a good press but I hate to just throw money at a problem and hope it works.
