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Is it possible that the problem is in the case itself? That old type ejection port doesn't leave a lot of room and if the case expands in the chamber enough, it might be too big to make it out the port. That would explain why you can cycle unfired rounds OK.
Here is an idea. Take an unfired round, preferably one you actually cycled through the action. Use an inertia bullet puller, or cut the case neck, to remove the bullet without enlarging the case neck. Place the case in the chamber directly (not easy), then see if it extracts and ejects OK.
Jim
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