Originally Posted by
Mauser308
Out with the vernier's - and a fired case that was sticky next to an unfired that runs in and out with no issues. Measure at the same points up each case and compare all the critical dimensions, web, neck, shoulder, lengths and see if you are getting a dimensional issue between once fired, twice fired that are sticking and brand new unfired. That will tell you if the dies aren't sizing back correctly. Also, a good inspection of the fired cases for anomalies that might indicate overpressure including case web expansion. As suggested before, book max loads may not be safe in every rifle with every combination of components so double check that the loads aren't hot and overstressing the brass...
Possible other issues, annealing the brass if it's work hardened and not springing back corrrectly? If the thing works with virgin rounds with no issues then the primary extraction while maybe not 100% is sufficient. There's an issue somewhere in the sizing - I've had this before with several rifles including Mausers with heaps of primary extraction and tighter chambers where the first firing is OK, second OK, third pop every other round out with a rod. I'd be picking brass annealing and die base sizing or similar combination of factors resulting in the dies not squeezing the cases back far enough. It's a true pain when it happens!