Yes, you are correct on the headspace factor. I did wonder as the ladder I shot was made of both virgin and once fired brass. I'm pretty sure the defective round was a once fired case and my FL die is set for minimal bump as I prefer to chamber a round with slight "feel". But, I know with newish brass it can take two or three firings for a case to reach max stretch for a chamber, requiring a final and permanent resetting of the FL die for perfect brass sizing. It might be a case that needs another firing or two to max out. Still surprising though that the primer didn't ignite with repeated firings.
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