I also think this may be an excessive HS issue. I am not convinced that your rifle has excessive HS but is it possible that the brass you are using is creating an excessive HS situation? Do you have a device that will allow you to accurately measure from the case head to the datum ref. point? If so measure the 223 cases you have and compare them to a known standard such as a 223 rem go gauge. You can quickly eliminate a variable. I have a possible explanation as to why your results are better after you uniformed the pockets, this will sound counter intuitive but I observed last week loading 223 ammo and was surprised. You said that you took the cases that did not fire and decapped them uniformed the pockets reprimed them and they worked. I will assume you de-primed them with a FL sizing die and offer the following explanation, and then Ill put my nomex suit on. I made a simple device by partially reaming a piece of barrel and fashioning it in a way that it could be fastened to my caliper to measure the base to datum of my cases when I was sizing them. Start with a fired case from my rifle measure and set caliper to 0. Now I slowly lower the sizing die checking my results as I lower the die. I expected to observe that as I lowered the die the shoulder would bump back and I would see a -.001 ect. What actually happened surprised me a bit the case actually "grew" a little before the shoulder started to push back. I suspect that some dimensional differences between my dies and the chamber caused the cases to be squeezed a little causing the shoulder to get pushed forward a bit before the die could come in contact with the shoulder to move it back. So if you had cases that created excessive HS then you decapped them and your dies like mine squeezed that shoulder forward a bit it could correct the HS enough to make the FP strike OK. Short HS on your cases would explain why they would not fire in your buddys rifle. Im just throwin some against the wall YMMMV
^^^THIS^^^
LC is 5.56 brass
So, if you indeed did use a .223Rem FL die to de-prime, it is very likely that the FL die 'squeezed' the case body as you de-primed. Any subsequent 'reaming' of the primer pocket, or change in primer make/model is inconsequential...
So, back to the FL die. Did ya use one to de-prime?
If so, ask yourself...where does that 'squeezed' brass go???
Answer, it flows UP toward the case mouth, as the die is supporting the rest of the case...
So, ineffect, by way of your de-priming operation via FL Die, you (without even knowing) INCREASED case shoulder length of that 'unfired brass'. Thereby, the initial "excessive headspace" condition you introduced by inaccurately (read:incorrectly) setting it TOO LONG, was in fact mitigated by elongating that brass when ya de-primed it...
It's either that, or the 'voodoo' primer pocket reamer fantasy you deduced from thin air, based on a flawed premise that defies all logic




