I am sure this has been asked before

KnotRight

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I was running some 6.5 CM brass through the resizing die and trimmed them. A few of them would not fit into the case gauge. Reran them through the resizing die again and they still do not fit.
How can this be?
 
Check the rim to see if it is keeping the case from going all the way into the gauge. A small burr can cause the case to fail the gauge test even though it will generally not keep the round from chambering.
 
Are you neck sizing only, bump sizing (neck and bumping the shoulder back) or full length resizing? Have you confirmed that you are pushing the shoulder back by 0.002" when resizing?
 
Charlie R, I am using Hornady FL dies. 90% of my brass is once fired from the range. Out of 100 cases I might have 5 to 7 with this problem.

Charlie, I will check the rim because that is what is sticking out of the gauge.
 
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I am to the point that if there are only two to five out of a hundred that do not fit in the case gauge I just throw them out. I just do not want to waste my time with them. Now if one after the other are not fitting then I investigate to see what is going on.

Also I have found more problems with Federal brass then Hornady brass. LC brass I very seldom have a problem with.
 
If they don't fit after resizing them- I toss them out. I used to struggle and use a small base die, I've even shaved down my shell plates to get it to size that last little bit. It's not worth it- though you say they're one-fired, I'm guessing you have some that were loaded hot. If the head area is stressed/overworked, even running it through the die, it'll be too brittle to take the new shape.
 
Charlie, I will check the rim because that is what is sticking out of the gauge.

So it is not a matter of the case almost going in but not quite far enough. Headspace is not going to be the problem if that is so. If the rim is sticking out, it sounds as if the rim is the problem. I would be very surprised if the body of the case was the problem.

Take one of those problem cases and see if it chambers and extracts easily in your rifle. Also try to put one into the gauge base first to see whether it goes in. It should go in a ways.

I have this situation happen frequently with 223 and 45 Auto and have learned just to take a file and make a swipe or two on the rim. It almost always works. The cases will still fit into my chambers even if I do not hit the rim lightly with a file.
 
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