I like the first comment. The bullet tip may be touching the seating cone shape before the ogive. Verify it.No full length bushing die sizes the entire neck. Just a couple of suggestions:
1. Make sure the seating die is not touching the tip of the bullet
2. Perhaps look at using a Wilson hand die and arbor press to seat bullets
3. How are you measuring the .005 variance? Are all primers set under flush to the brass so as not to affect the measurement. You should be measuring cartridge base to ogive and not overall length.
4. Make sure you are not crushing the powder (ie compressed loads). This will push the bullets back out over time.
Dave









