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Checked the dies and sized some known good federal brass, all ok. Went to the range and carefully shot the rest of my work up, things got a lot better. As I had more powder the buldging and primers backing out subsided . I think I found my sweet spot around 45-46gr of Varget. My next work up (fine tuning) will be in this range. Thanks for all the info regarding this problem. I would of never thought that too light a load would of done that to the brass.