I'm not thinking it's an over-pressure problem unless there's something I'm missing. Regarding the chamber, this is a custom build and the chamber was honed by the smith using a new, custom hone - I was thinking that perhaps the chamber was honed a little tighter than SAAMI, given the seating problems, rather than being sloppy. Is there another way to think about this?
Good information.
As far as "another way to think about this":
excess upsizing leads to excess down sizing. They feed each other.
Where cases have expanded on firing there will be a web-line. That is the widest point of your cases. Can you measure this point with new and fired cases for comparison?
It may indicate chamber clearances as very tight, or very loose if so.
Finally, you mention oversizing - since I was focused on bumping the shoulder and didn't size the body all the way to the base, I was thinking I was undersizing the case, not oversizing. Were you saying that by not fully sizing the body, I was leaving the case itself oversized?
That's not what I was thinking. You wanted more sizing of necks, and shoulders, and now bodies. More more more..
There had not been a basis for more sizing until you mentioned that you can't get the bolt to close due to interference at the webs.
Case webs are very thick, and do not usually grow a lot, quickly, -unless:
1.
High pressure loads (excess single use web growth can be a pressure problem)
2.
Sloppy chamber, allowing so much growth to begin with. Tight chambers don't allow so much growth unless #1/#3
3.
Insufficient breech support, allowing chamber end to expand excessively on firing. The brass goes where the chamber goes.
Now you could go to a special small base die to smash the webline enough to allow rechambering. But that's not a 'good' thing to do. Brass thickness would be rolling upward, thick toward thin, eventually leaving webs thinner, feeding on itself. That sizing will never put the brass where it used to be, and pockets will open at a higher rate, so you'll be replacing brass at a higher rate.
A small base die will not cure
causes 1,2,3, and I doubt you wanted to get into band aiding your custom gun.
Once the problem is determined, that's when you should decide how to proceed, band aid or fix.