Okay, here goes.
This is the set-up I am using. It is a Hornady "Headspace comparator" body with Sinclair inserts that are cut with a chamber reamer.
This is the unfired case, 1.563", as it came from Lake City in the Lyman .308 case gauge and it's reading on the comparator. This brass was neck sized to ensure proper tension as it passed the gauge upon receipt.
Next is a case I sized until it freely chambered in the rifle. I then let the action (M1A) slam closed on the case in the chamber several times to see if it reduced the size any further. It did by several thousandths and the result was 1.580". As you can see it stands out of the case gauge by a considerable amount. Also seen is the depth end of the calipers I used to get the .019" above the case gauge upper step or gauge maximum dimension.
This is the dimension of a fired case with the gas system turned off. The ten shot average was 1.588". Then photographed case was a random case from that lot and obviously above the average.
This shows no interference from the case head dimensions.
The average for fired cases with the gas turned on is 1.593" but is not really of concern.
Where my concern lies is with the fact that the unfired Lake City case and the Lyman case gauge seem to be in agreement while the dimensions of what the rifle chambers are much different.
What we have is a rifle that will chamber X, but a gauge that wants X -.019" at least to be within its maximum "spec".
This seems like a large difference to me.
What is the difference, functionally, between out of spec bolt headspace and a case that must be pushed the .019" distance(not including mechanical headspace) into the chamber before the primer is detonated?
If this is within the accepted range of tolerance, then okay. It just seems excessive to me. Especially in terms of case stretch and potential for head separations. I'm not trying to create a miracle for my brass as I know it is abused by the platform. Also, I am not exactly fretting over these issues. I simply want to better understand what is happening and how to limit the stress on the brass if for no other reason than "just because" it is interesting to me.
Hopefully, with the 1.630" headspace gauge coming I can get some sort of calibration from that known dimension. I don't like blindly adjusting a die and squishing brass even though it works fine for many people. I have done it too, but want better.