First..........I havent' reloaded in about 20 years.
Second...........I had the RCBS Rock Chucker when I did reload.
Third.........I would think that even with the dies being used, I can't see them "wearing out".
Fourth.............I would think your problem lies somewhere in the resizing step. Can't really speak about the Hornady dies, I used the RCBS ones.
I assume you are talking about the OD (outer diameter) and not the OAL (over-all length.
I guess it may help if we knew what caliber you were reloading for. But still, if they are tight in the chamber and not able to be ejected easily, I would think it is the resizing step. Unless the OAL is too long, it may be grabbing (being pushed) into the lands and grooves of the barrel and it may be catching the bullet making it hard to eject/extract.
I assume you have a set of vernier calibers. Did you try measuring the length also to compare it to a factory bullet that is close to the one you are reloading?
Hell.............I don't know. :lol: Like I said, it's been 20 years.
I am sure someone with more knowledge will be along in the morning to help you out.
Good luck with your reloading. If I had more time I would like to get back into reloading. For now though, it is factory rounds for me.
