Some of the AI chamber reamers and gauges are setup to already bump the unformed case shoulder in the chamber so the round stays in place when forming. Thats not always the case though.
It just seems to me that the firing pin is rubbing against sometimes causing a inconsistent strike. If you are using already formed brass then you might be able to size the shoulders down far enough to cause this problem but then you would see crimps in the brass if you are pushing it that far back. Use a piece 40 s&w to measure how much difference you have between the fired and unfired stuff. Just measure the OAL the pistol case square on the shoulders and it will let you know the difference in your HS.
It just seems to me that the firing pin is rubbing against sometimes causing a inconsistent strike. If you are using already formed brass then you might be able to size the shoulders down far enough to cause this problem but then you would see crimps in the brass if you are pushing it that far back. Use a piece 40 s&w to measure how much difference you have between the fired and unfired stuff. Just measure the OAL the pistol case square on the shoulders and it will let you know the difference in your HS.