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I've been running the expander far too high in the die body. Should have factored that in since the other function of the die is decapping (with the pin in place), so the pin has to be in reach of the fired primer and a bit more to punch it out. Just didn't think it would matter as long as I wasn't pushing the expander to the bottom of the case and buggering it up in the flash hole area.
Another fact I've been pondering is that I've got the Redding T-7 mounted on a Franklin Arsenal portable stand so I could do brass monkey chores in the family room, and I wonder if it imparts enough instability that the press leverage isn't smooth enough. Clearly there is more than sufficient leverage to crunch cases, but obviously that isn't my objective.
I'll try the expander much lower in the die body tonight and will switch out my lube after I've tried repositioning the expander. Failing that, I'll switch to one of the bench mounted presses to see if I'm inducing failures based on new dynamics.
Thank you for your input.
Best,
Brad
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