You also might check for "neck bulge", this is caused by the roll crimp catching on the top edge of the crimp canalure as the bullet is being seated. If you change bullets, you often need to change the crimp/seat settings.
My Ruger Vaquero in 44-40 used .427 bullets, every thing fit and worked on the first batch of 2000. The next batch was with a different bullet, I tried adjusting everything with the RCBS dies. I got it to where 60-75% were fine, that is still 500+ cartridges that were bad! I hate to admit it, but the LEE Factory Crimp Die cured this on all batches from then on. 44 special/mag., have thicker case walls and will bulge worse if you aren't adjusted into the canalure properly!
Ivan