Rounds wont fire.

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I am no expert. If I had a dime for everyone here that was smarter than me, I would be rich. There are a lot of smart people here. Important to run tests to see what is occurring. I learned about small base dies right here on THR. I used an RCBS small base. Small investment that worked for me.
 
Take a fired case from your other AR and try to load it into your new gun. My bet is it won’t chamber. You most likely have a tight chamber.
 
Any thoughts or ideas? Going to take it apart and clean it and lube it well. My friend has the same issue with his juggernaut. We got them same time.

Forgot to mention as well that new 5.56 rounds worked perfectly fine in both guns.

Move this to the reloading forum, as it’s a reload problem.

Obtain a case gauge and compare the factory ammunition that runs in both, to your reloads that don’t. Note the difference and adjust the dies/trim so your reloaded rounds are indistinguishable from the factory ones when case gauged.

You’ll be in business at that point.
 
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With the case gauge the ones that didn't fit were just a hair over the top of the gauge. I had some that would and some that wouldn't. I was able to quickly sort the two out.
 
I had the same issue as the OP with two ARs. Like many have said, it was due to excessive case head to shoulder datum length. I was able to size cases sufficiently with a standard Hornady full length sizing die, but it had to be adjusted such that the shellholder essentially touched the bottom of the die when actually sizing a case.

Though a small base sizer is perhaps the best solution, I suspect most standard sizing dies can be adjusted to work. Same with a case or cartridge gauge. They are a good way to check finished rounds, but aren't necessarily essential.
 
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Get small base dies. This will fix the problem. Who actually loads for an AR (especially more than one!) with anything but small base dies? (The question is rhetorical. No need to answer.)

I mean, I don't handload for my AR but now I know what to look for now.
 
When I experienced the same problem 12 years ago everyone kept telling me I needed small base dies. Wisely I colored the cartridge with a marker and chambered it to find problems with shoulder dimensions. I’ve found that is the downfall of this cartridge.
 
Get small base dies. This will fix the problem. Who actually loads for an AR (especially more than one!) with anything but small base dies? (The question is rhetorical. No need to answer.)
I haven't been able to find any small base dies for hornady, any compatible suggestions?
 
When I experienced the same problem 12 years ago everyone kept telling me I needed small base dies. Wisely I colored the cartridge with a marker and chambered it to find problems with shoulder dimensions. I’ve found that is the downfall of this cartridge.

I've tried this with 3 different bullets "without a prime for safety" at home with no rub off on both the ARs
 
I've tried this with 3 different bullets "without a prime for safety" at home with no rub off on both the ARs
Interesting. I'm still going with something about the shoulder. I even had one die that would mess up when I seated the bullet.
 
Interesting. I'm still going with something about the shoulder. I even had one die that would mess up when I seated the bullet.
I'm going to completely clean and thoroughly grease the 2 guns and see if that makes a difference. I did make the mistake of taking right out of the shop to shooting without doing this before hand. All specs in the bullets come back below max I'll he doing that Saturday and will post an update!

Thank you again everyone for the imput
 
OAL on the reload is 2.250
Joe, had issue with a rifle my buddy built with rounds doing the same thing. Dropped the OAL to 2.200, using 55gr fmj, and it started eating em like candy. NOW with that being said, we also started over with our powder charge to compensate for the drop in OAL, so load a couple and use the beginning charge weight for whatever powder you are using and work up from there. See if dropping the OAL works.
 
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I haven't been able to find any small base dies for hornady, any compatible suggestions?

That is because most small base dies are made by RCBS, as I have found. I prefer Lee Pacesetter dies (3 dies, dipper, and data from lee) for my loads myself. Thankfully dies from most brands are the same thread count for your reload press. But double check to make sure.

https://www.midwayusa.com/product/1011716114
 
Update, cleaned and properly lubed all parts just to be safe. Loaded rounds with prime only and they fired no problem but a little resistance when ejecting but not much. Tried 30 rounds of original reloads that werent working and they went 30 for 30 flawlessly in both ARs. I also trimmed the OAL as suggested and reset my seating die to remove the crimp feature. I trimmed the case to slightly below max length and seated the bullet in a little more to achieve this. In doing so both the ARs function flawlessly now. The resistance of self ejecting a round with only a prime is extremely smooth and only expected resistance from the spring. Didnt go to my usual shooting location so I was only able to run 30 of the old load and 60 of the new load through each AR. I am however splitting the reloads and only using the old reloads in my older AR that they function in without a problem and inky using new reloads in the juggernaut till only the modified and correct improved rounds are all that remain.

Thank you again every for the help! Made finding the solution easy and with vertually no frustration on multiple trial and error!
 
1. Using bullets seated without crimp?
2. Tested in the juggernaut?
3. And the cartridges both chambered and then extracted w/o any trouble?


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The bullets were with a crimp and tested in the juggernaut. I did however do all that you reccomend and cleaned and properly lubed "it was bone dry from the factory" my first mistake not checking that I'm extremely embarrassed about. And adjusted the bullet . The original loads that didn't work did fire now without incident but I adjusted the bullets and they work flawlessly now with all suggestions applied!
 
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