"The US FA ammo was obviously hotter. "
I don't know why, but this happens. Some lots of ammo are just much hotter than others. I recall a lot of IVI that was blowing extractors off target rifles. I reported this to the military and they tested it. They reported back to me that it was hot, but at 62,000 psi, still acceptable.
308 is loaded to SAAMI specs. When Winchester designed the cartridge, they modeled it on the military caliber. Dimensions are about the same. There are some differences:
Military ammo is loaded to specifications that include things like a min and max pressure at a pressure port down the barrel. SAAMI is loaded only to a spec of max chamber pressure.
Military ammo has a spec relating to muzzle flash and smoke. Not a concern to SAAMI.
But you are concerned with pressure and dimensions. The dimensions are close enough to be interchangeable. Pressure limits are the same.
Way back when, pressures were measured using lead and copper crushers in pressure barrels. A hole in the side of the case allowed a piston to move and compress a short piece of copper or lead cylinder. (About a quarter inch in diameter and about a half inch long, as I recall. About the same size as a 38 wadcutter bullet. After firing, the slug was measured with a caliper and the amount it shortened was converted to pressure, using a table. The units of pressure were called CUP (Copper Units of Pressure) and LUP (Lead Units of Pressure).
I conducted thousands of such test shots. It took time to do each one. A real pain. Then the piezoelectric transducer method of testing was introduced. A transducer changed voltage on an oscilloscope and gave instantaneous pressure readings.
For reasons unknown to me, for some calibers the location of the transducer in the chamber was at a different place than the crusher port would be. For this reason the pressure tables for each test method are different, although the effective limits are the same.
That is, if a round is too hot, it would be too hot with both test methods, although the numbers quoted would be different. Think of speeding. If you are going too fast, it does not matter if your car speedo is in mph or kph.
Of course, with speed, you can multiply by .62 and convert one to the other. Not so CUP and pzeo PSI. Not only are the test locations different, and the units different, but the test locations vary from caliber to caliber.
Why all this history, you ask? Because when 7.62x51 was developed we were using copper crusher pressure guns. The max pressure was/is in the order of 55,000 CUP. But, and here is the whole cause of the confusion, in those days the tables generated CUP units of pressure, and we all referred to the units as PSI, because, so far as we knew, that was what the pressure was.
When the pizeo transducers came into vogue, the civilian world was careful to refer to the old system as CUP and the new system as PSI, so as to avoid confusion as to what was being referred to. For a long time both systems were being used. Maybe someone is still using CUP or LUP equipment. I have not seen one since 1965.
But the military was not concerned about confusion of two pressure systems, because when they wrote their specs, there was only one system - CUP. So they said the max pressure was 55,000 PSI, but they measured with the CUP system.
When the 308 was developed, SAAMI said the max pressure was 55,000 CUP or 60,000 psi. Same pressures- measured two different ways.
The pressure limits quoted above are simplified. An actual test is a 20 round sample. There is a max single round limit for the test and a maximum average pressure for the test. Going by memory, the limits are in the order of about 63,000 psi for a single round and max average for the 20 of about 60,000 psi.
These pressure look high. Most lots of commercial ammo are deliberately loaded to a maximum average pressure of around 57,000 psi.
Military ammo is loaded to very similar limits, but because military documentation will mention a limit of 55,000 psi, the myth has developed that 308 is hotter than military. Not so. When the military say 55,000 "PSI" they really mean 55,000 "CUP".
I have tested hundreds of different lots of both 7.62 and 308 ammo. Almost all of it ran in the range of 55,000 psi to 59,000. I saw no evidence that one flavour (NATO vs Commercial 308) is hotter than the other.
Military brass usually has a higher web (the solid section of the base). This forms the solid plug to seal the breach. If a rifle had a shallow chamber, allowing the case head to protrude a bit too much, a high base would seal the breach whereas a low base could blow. Some military automatic rifles (M14) have feed ramps that relieve part of the chamber edge, creating a potential for a case to blow.
In general, such rifles are best shot with military cases. Not because pressures are lower (they aren’t) but because the case web is thicker.
One rifle that comes to mind is the M14 tuned by one of the marksmanship units. It was the Army Unit, I think, but maybe a different one. They took so much metal off the feed ramp that the rifle would be dangerous with some kinds of brass.
I had occasion to examine a case involving a blown case head. The shooter was not seriously injured, but it could have been worse. Turns out the military 7.62x51 cases he was using (Santa Barbara) had a very, very low web and his rifle had a shallow chamber. As he said "I never had a problem before!"
An article in the NRA magazine The Rifleman last year made a passing reference to the fact that military ammo is the same as SAAMI, but looks different because of the old pressure system. I meant to clip.
I cleaned out my file cabinet a few years ago and threw out a lot of stuff that had been of interest to me. Never occurred to me that anyone else might be.
The strength of my convictions does not make me right. Here is where I am coming from.
In the RCAF I was an Armament Officer. I was responsible for small arms and ammo, and the bigger stuff, including rockets, guided missiles, homing torpedoes, bombs and depth charges. We used TNT, C4, RDX and nuclear. Weapons were#4, C#7, Sten, Sterling, FNC1, BHP and Bren. I got to play with them all (except the nuclear stuff). Our paperwork weighed more than a bomb load and I read most of it.
After the RCAF I went to work in the R & D labs of the CIL ammunition division. There I conducted testing of R & D projects, with pressure testing a common test.
I have been hand loading since 1963 and for the last 15 years I have been the technical director of a small ammo company making specialized ammo for the military and police forces.
In conclusion, shoot 308 in your 7.62x51.