Stubble, your observations and experience parallel mine in many ways.
I have a 308 Norma Mag that was built two winters ago by Bill Leeper.
This rifle reaches "expected" max velocities with anywhere from 3-5 grains less powder than is listed as a max in any manual I have.
I know it has a "snug" chamber, due to sizing issues with brass previously fired in another rifle.
It also sports a 26" Custom barrel and that may be a factor, as you observed.
But it would be a bit of a surprise if someone not as cautious as they should be, choosing a max listed load and trying it.
I'm betting the bolt would be plenty tough to open, lol.
I played with the STW quite a bit.
Had one that you could not get enough of one of the recommended powders in to reach proper velocities.
It never did show any signs of pressure.
Another one topped out at 3 grains less than max load listed.
I have a 7mm RUM right now that would be trouble if one loaded a recommended max load of Retumbo behind the 160 and fired it.
The list goes on...so many variables.
A person really needs to be observant so as not to get into trouble.
FWIW, On new brass, I allow up to .0009" expansion of the web area on the initial firing. Any subsequent expansion is taboo, in my books.
Regards, Eagleye.