When I went back east I visited with the friend who was having the problem. I also took my Dillon case gauge. What we finally found out was when seating the bullets the shoulder was being squashed a bit. This was enough to keep the rounds from seating correctly. We set the small bse dies up...a little differently than he had. We got everything set correctly and did a chamfer on the inide of the case neck...and voila'...no more problems. Oh some of the rounds he had were evidently fired in machine guns. As someone else stated I too also size cases with a wait on the 2nd sizing when using military brass....to reduce springback. Yeah it takes time...but usually worthwhile. Now days I only use match brass in 30-06 and 7.62/308. Most is all very good stuff. I al at present sizing and taking primer crimps from about 10,000 5.56 brass I am going to be loading on my Dillon 650. I want no or little problems when loading all that ammo. Should last me for a long time. I have loaded about 500 rounds for initial set-up and have experienced no problems shooting some in 2 semi autos, a bolt gun and a Contender. I figure loaded ammo takes up less room than the components do and I do have all the powder primers and bullets laying around anyway. Thanks for all the suggestions and help. I left him the Dillon case guage. He has had no problems after getting everything set up correctly. He IS one of the most diligent reloaders I know(I taught him to shoot and reload) and would have finally gotten it right anyway...but he was somewhat stymied at the time. Thanks