Just a guess, but sounds like typical undersize cylinder throats (.355" - .356") are swaging your bullets down to typical bore groove diameter (.3555" - .356"), or worse yet - under groove diameter.
Speaking strictly of cast bullets, most bullet makers recommend bullet diameter be at least .001" larger then groove diameter - to hold the rifling under pressure. My feeling is that, .002" larger, is better. Figure a .356" bore groove diameter, & cylinder throats should be a uniform ID of .357" minimum. .3575" - .358" ID would be better.
Not that this is a chiseled in stone, hard & fast rule, but IMHO at least - it's a real good starting place.
There are always work arounds: a faster / slower powder, or a softer / harder bullet alloy - to name a couple.
To get a rough idea of your cylinder throat ID, drop a .358" sized bullet (unloaded / bullet only) into the chamber - nose first, & see how much pressure is required to push it through. If it just falls through, throats are probably .359". If it takes a slight push, probably .3585". A very firm push, .358". Gotta' jam it? Probably .357" - or less. Etc., etc..
Measure your expander. You need neck tension, but too much on a soft (swaged) bullet, can in itself, reduce bullet diameter. I switched to a Lyman M die, for .38 / .357. The Lyman expander measures .355", which is .001" bigger then the diameter of my Dillon expander. Takes an extra step, but worth it for me. Every little bit helps, & I use a harder cast 158LSWC from Dardas.
One last tip. Go to Hodgdons online data page for your caliber (.38spl?), & try 12 rounds at the listed minimum starting load for Bullseye (or ww231, titegroup, etc.). For grins, load 12 more at 0.2 grains heavier charge. Then, finish these loaded rounds off w/ a VERY light crimp - maybe .002" - .003". Nearly no crimp, in fact.
Sounds crazy? That's what I said till I tried it - based on someone else's recommendation. Groups w/ both my 686, & 64 tightened up exponentially, & I learned how to smile at the range, again...