Yup, I'll second that notion. DO NOT fool with the seating depth, it is not the problem, but you will create one if you change it, AND the primer at the same time. Effectively, you will be reformulating your load all over again.
On another note, getting back to the issue with the " lowly 140 grain bullet". There is a lot to be said for it, it smokes whitetail in there tracks, shoots flatter than a 22-250, and if shots are inside 500 yds, the added BC isn't really a issue. Drop a 140 BT, TSX, or TTSX, and send it out at about 3400, and the deer in your crosshair is guaranteed a pick- up ride. Don't take my word for it, read Layne Simpsons own words. (I think he knows a thing or two about the cartridge). However, I am not saying there is anything wrong with a 160 class bullet. One of mine is very fond of 160 grain Speer Grand Slams.
As far as your " fliers", in retrospect, and after re- reading your post, I gathered that you did get good groups when you went to another bullet, and assuming you used the same primers as before, it COULD be that the Burners after all, but I do not think it is a jacket separation issue. Barnes QC seems to be spot on these days, and I am very impressed with the bullets that I have shot. I am however, not familiar with the Barnes Burners, until I heard about them from you.
Any way, I hope you figure it out without having to unload and reload a bunch of ammo. The one and only last thig that comes to mind COULD be powder bridging in you powder funnel, when you go from round to round. That would make one load with a lighter charge, and another with a heavier charge. I have done that plenty of times, and caught myself before seating the bullet. Just another thought! Take care, and I hope things work out.
