Thanks for all the input, was hoping to find someone to take the rifle to and have them look at it, it seems to be a rare trait nowadays, Clay Spencer was good at it, he had about 8-10 primary things he would look at then move on to secondary and then little things that no one would ever consider. Unfortunately I had a falling out with him, both of our personalities are pretty strong and when a disagreement happend it became a nasty clash. He really is a hell of a smith and I probably took for granted what he was capable of especially after running into smiths that can't even devlope a load for their personal rifles.
I've checked the paralax with the bobble head routine and it's accecptable, extreme movement from one side to another might be 1/8" at most, nothing to account for a change from a .2" to 1.5". Changed rests and rear bags, even tried loading a bipod, same buckshot patterns looking back at me.
The accuracy started falling off before 200 rounds on all the rifles, it was right at the end of load development on all of them. Right when you think you have it tuned down to a small window, where 3-4 loads are giving you high 1s and it could just use that final tweaking to get you there. Those are the loads I'm looking for, ones where a slight variation stays in at most the 2s.
I start with 25 pieces of brass, fire form them, neck size then start load development. After 3 firing I start FL sizing and trim to length. So these 3 have gone to pot around 100 rounds. I really don't put much creedence in the first virgin brass firings, brass hasn't fully formed yet so pressure curves will be slightly off and the leade hasn't been smothed out yet so a lot of times those loads are just with powder that is left over (1/2 lb or so of a lot) and I just get an idea of velocity ranges I can expect.
After the first 75-100 rounds the barrels get JB'd with the non embedding paste then a good sweets soaking just to try and ensure that all the break in copper is gone. With this one I've gone at it the past couple of days, it's gotten the regular routine, sat overnight with wipe out foam in the barrel twice, hit with 40x, TM and bore shine. No patches have come out blue but I do see some faint lines of black on some of the dry patches, may be nothing, may be some tough carbon, may be my bore guide giving up the ghost under the nonstop solvent barrage.
The powders that I've used have been H4831SC, H4350 and RE17 in this barrel, used the same ones in the 6.5 Sweede Imp and the 6.5SAUM saw H1000 and Retumbo.
Hopefully I'll be able to borescope it Sunday, I'd like to see something that explains what is going on, wether it be fouling or some kind of pitting and ate up rifling, the barrel would be shot but at least I would know.