How much of a firing pin strike are you getting on the reloads? Are the primers going off or are you getting just a "click"?Should mention that I pulled a reload and a factory bullet when I got home and the factory round went off but the reload did not (just primer).
It has me stumped.
FL sizing shouldn't be an issue if factory ammo is going boom. The factory ammo probably has a shorter head to datum length than your FL sized brass.
My first guess would be the CCI 400 primers. I use nothing but Rem. 7.5 BR in my AR.
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