Back to Basics seems to be the answer. I should have addressed the cases first but counted on CH4D dies be almost perfect. In this case, I believe they are not full-length sizing correctly.

I happen to have some surplus 11mm Mannlicher rounds and they chambered and extracted perfectly. I tried this with ten rounds and spent about 10 minutes just chambering and extracting. Not one issue.

Out comes the micrometer and the Buffalo Arms cases (50-100 Starline) are very close to specs with the neck being 8-10 one-thousands too wide. With me zealously chambering the rounds, with apparent no issue, there is to much friction from the oversized necks for smooth extraction.

Tomorrow, I am going to take one of the old rounds and run it through the dies to see if the CH4D dies are at fault. Feeling like there is an issue between the dies, cases, and chamber. Will do a chamber cast tomorrow too.

Again, thanks to all for your help and stay tuned.

Randy