Your die could need cleaning, causing cases to stick while sizing. Ultimately, spring for a carbide die if you can. They are worth it.
Regarding dimensions. You are giving dimensions for a finished round, but measuring just after sizing. Remember that your second die, the expander, is going to increase the OD of the case a tad. And finally, inserting the bullet in step three can also increase the OD. So don't worry about measurements until you have a finished round.
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If you want to shoot...shoot...don't talk! Tuco
USAF Munitions 1969-1992
RVN 1972-1973
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