Quote:
Soot on the outside of the case is more likely a sign of low pressure than high.
I'm still betting headspace.
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I agree that a sooty case can be a sign of low pressure, but once fired neck sized brass (aka fireformed) should be larger than the unfired brass, thus filling up more of the chamber (and eating up excessive headspace), so I'm not quite sure if headspace is the answer here.
Homesick, are you using some type of shoulder bump die?
Can you post a pic of the normal and flattened primers?