Just the first thought that struck me after reading your post a couple of times. Bullet creep. Reasoning follows:
developing a non lead load
I've never used one, but aren't "non lead" bullets longer then the same weight lead core ones?
max load of IMR 4350 <snip> worked up to 59 grains
IMR 4350 is my favorite 30/06 powder. However, I seem to remember that I was compressing the charge with 150 gr. lead core bullets at less then 59 gr. Now, I found that 4350 likes a little compression, but... If you're using a longer bullet loaded to the same OAL it seems to me you would be compressing the charge even more then usual.
My last trip to the range ... I went to the range yesterday
Were all the rounds, the ones used during both trips, loaded at the same time? How much time between trips? In other words, did the second group of rounds fired have time to sit between shooting sessions giving the compressed powder a chance to sneak the bullets a little further out of the case.
an AOL of 3.355"
Did you measure the second batch prior to shooting them on the second outing, or was the measurement taken when all rounds were initially loaded?
Additionally, if the rounds were crimped they would be less likely to creep, but I think most of us don't crimp our rifle rounds. Lastly, how far off your rifles lands are you? Naturally, if you're close, as people are want to get, it doesn't take much forward movement of the projectile to hit the lands and make chambering the round more difficult.
Just a thought.