218 Bee said:
"...I can fully rechamber the spent round if indexed the same as fired. The spent round will chamber if rotated, but it's not a full lock. the action lever is locked but is flush with the frame not in the full lock with the lever above the frame. "
Rick, I hate to sound like a broken record, but think about this:
Your fired cases will not chamber and allow full lockup, unless they are properly indexed. How can this be? They should go back into the hole they just came out of...and so they do, if they're properly indexed. Your rifle is not locking up as it should, which is allowing the pressure at the moment of firing to spring the action enough so that the case head is no longer aligned with the axis of the bore. Then you F/L size the case, which allows it to be chambered again. But I doubt that the head of the case is being completely re-aligned properly. This in itself could be the root of the stringing you're seeing in your loads. You probably already know that alignment, of the bullet and the case, with the axis of the bore, is a huge factor in repeatability, hence accuracy. This is the reason that neck-sized cases are more accurate than F/L or new factory ammo--they are fitted to the chamber by fireforming so they are more perfectly aligned with the axis of the bore. Your fired cases will always have that mis-alignment built into them unless you can correct whatever it may turn out to be that is causing your action to do this.
But there's a bigger problem.
I'll bet that your cases are growing as much as .005" after being sized; this would be due to the extra stretching in the web area at the moment of maximum pressure. At this moment, your action is opening slightly, twisting, this must be why the fired case has to be indexed before the action will lockup. Even then, it's not fully locking up or you'd be seeing better engagement of the latch in it's recess in the underlug.
So, if your overworked brass should fail, and you have a head separation, it will happen with the action partially open. This would not be a good thing.
I hate the thought of having to send a rifle to the manufacturer for repair, but I strongly urge you to do so. Fiddling with or replacing the forend is not going to solve the problem. NEF will take care of you, to the point of buying back the rifle for what you paid for it, should it come to that. Maybe all it needs is to have the latch itself replaced. Maybe the rifle was assembled, and never final fitted. I'll bet that this happens a lot--they put the parts together, and the rifle closes and locks up. Someone using factory ammo exclusively would never know the difference.
Maybe all you need to do is back off your powder charge a bit until you no longer see this happening. One thing is for sure, in my opinion--you'll never get the best the rifle has to offer in accuracy if you can't use fireformed, neck-sized brass for your reloads.