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Andrew,
I had similar problems with my .45 rounds when I was shooting 230 and 255 gr. lead, but only in certain brands of brass. The 255's would not chamber if used in Federal cases. So, I was forced to separate that brass from the other. The S&B stuff was the same way. You may want to contact Lee and get a Lee undersize die from them. I think they make it for .45, but am not 100% sure. This replaces your Dillon sizing die. They don't have enough thread on them to use the lock ring, but just drill and tap the toolhead and run a setscrew in to lock the U-die in place. I use Lee's u-die on my 550 for Super and .40.
CS
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