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Big bunny. Discounting practical jokers and well wishers, (helpful friendlies ???) Several thoughts crossed my mind. If I understand your post correctly, you neck sized your brass? Maybe some of the rounds were a bit hotter than the others.
You did not state if you checked case length. Maybe some of the rounds are a bit longer?
It could also be that some of the brass might just be a bit softer. I would separate those rounds, shoot them again to see if they have the problem again, in comparison with those that did not over-expand.
Don't know if the answer is there, but I hope it helps.
Paul B.
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