Show some pictures of your finished shells, they might give some ideas as to what exactly is happening.
What equipment are you using to reload? If you are using a Lee Load All, you might consider a MEC Jr.
I reload 20 GA on a Load All and the crimp must be firm, if not sometimes the petals start to spread and shot can come out. On the Load All, the shell must be oriented in a certain way to begin the crimp, else it will be bad. I load AA hulls exclusively and have not noticed a difference between between the old AA and the newer AAHS. I must add though I have not bought a box of AA shells in 6 years so if there is a newer version yet of the AAHS, I have not loaded them.
I load .410 AA hulls on a MEC Jr and by far this press is superior to the Lee Load All. I intend on getting one for my 20 someday.
I use the Lyman ShotShell Loaders guide version 5. There are recipes for STS hulls in that, but not specifically for Gun Club. Do the Gun Clubs have a nickel base? If so, as said above you might get one or two reloads from each. Make sure to check your recipes.