1.Okay, I. Have a plunger ejector, along with an extractor that doesn't work unless I try to fling brass 2 lanes over. Sounds like enough reason to extract the ejector. So it should affect brass dimension for the life of the brass, right?
2.As far as f/l sizing new, it barely squeezes at all. I just do it so everything that get cut is identical after being cut. Is there harm done??
3.After neck sizing for 3 firings I have thrown only 1 case out of 30 because of run out. Do I need to check other places, or do i have to go buy a neck mic and get my measurements on new brass?
The plunger ejector will cause the new brass to offset in the chamber before it is fired . Whatever offset is there will remain to some degree as one side of the case blows out more than the other .
The more you size a case down the more that offset can be.
I remove the plunger ejector in my 223 and take each case out by hand. That way the brass does not get damaged or lost . This may not be suitable for all situations so you have to work out what is best for how you shoot.
You could also have a gunsmith place a grub screw in the side of the bolt to lock back the plunger ejector during fire forming of the batch of brass. Then once they are formed the ejector can be unlocked , remove the grub screw from the bolt and carry on as normal .
There is no big harm done by sizing new brass except that if the new case fits with no problem then all you are achieving is to increase slop in the chamber .
You can't measure run out at the meplat (point ) of the bullet or on the ogive as this part of the bullet has it's own surface inequalities and wrinkles.
Bring the dial gauge back to the parallel part of the bullet or closer to the case neck. Some of the runout you measure is also case runout . You got to get that concentric fire formed case first so that later you are mainly measuring the bullet seating runout.
Bullet runout can also be a function of:--
Neck hardness consistency around the case neck .
Quality and straightness of the inside neck chamfer .
Quality and straightness of the seating die.
Suitability of the seating stem to the bullet ogive.
Skill of the reloader in seating bullets.
Design of the base of the bullet.
Surface condition of the inside of the neck.
Most of these requirements are taken care of by good dies and sensible reloading.
In a sloppy factory chamber getting a new case to fire form right in the center is hard . That is why they use tight base chambers in target guns . The chamber is already tight for a new case and may need to be sized slightly to get it in.
That way it has to be in center before it's fired .
What you can do is wrap a narrow strip of scotch tape ( about 3/16 wide ) around the base of the case just above the extractor groove . It should not overlap it's ends. Chamber it and see if it is getting tight as you close the bolt . Experiment with the number of the wraps until it is a neat fit . This then centers the case for fire forming and is only on the solid head part of the case that does not blow out with normal pressures .
I can't see that a neck Micrometer will help you in a factory chamber to any great degree . You should only be skim turning and not to any specific loaded diameter like you would in a tight neck chamber . You could use a neck mic to turn to a specific thickness of neck if you wished but that specific thickness may take off too much brass on another batch of new brass . So you would be changing it anyway.
It is simpler to just skim turn what you have in each batch off brass and don't worry about the actual thickness other than to preserve as much thickness as possible while still straightening up 70% of the neck.