Im not sure if I missed anything, but did you try one of your old cases that you did get to fire? That will at least take out the possibility its a headspace issue such as debris is stuck on the shoulder in the chamber. You may even cut the neck off one of your cases and if it fits but you full case doesn't, then its in the neck part of the chamber, obviously. After you do those two steps, its obviously the bullet. I assume since you said you lost some ogive to base length, then you must have data on your original. Make sure you didn't somehow get bullets mixed up and are using a differen't bullet. I doubt you are, but its surprising the little things we miss because we are so worried about something being much worse.
I mean .1675 of length is substantial. It kind of sounds like you lost your freebore somehow. Im not sure I understand that...Its possible you had some brass flow that got stuck due to overly long case length?? Maybe try running a brass brush down through from the muzzle if you havent already. Just be careful at the crown.
You can also push the brush up through the chamber end, and pull it back out after you get just past the throat area. I dont necessarily advise it, but ive done it in a pinch when I get a stuck case. The brushes fold backwards, so when you try to pull back out without going all the way to the end of the muzzle, it creates a barb that pulls basically anything out that is in there.
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