Puzzle solved, at least in my mind.
Working up brass today, a box of 50. This is load development brass so some were loaded hot others not so much. I settled on my hot 42 gr load a good while back loaded one box of 50 3 times with that same load. This is Peterson fat brass in a custom barrel. All 300 turned to 0145 when first purchased and worked great. Today I was randomly fitting bullet into fired brass and some of that 50 would not fit.
I assumed that once I turned brass to a given thickness it would stay close until end of life but I was so wrong. I turned to 0145 and was surprised at the brass removed. I have also learned how to find brass that has been subjected to extreme pressure. A small base die will let you know.
So to every one, the one or two that suggested exactly that with a bullet. The guys who prompted me to check chamber conditions, the guys that said brass is ruined (and you are correct) even the spell checker.
I appreciate it, thanks for taking the time to look and offer your opinion.
