Before I sent it back to the factory I loaded some pretty light loads and it was not quite as hard to open but not what I would call enjoyable. I have maybe 10+ different powders and some Trail Boss and I will try a couple different loads but in 30+ years of reloading I've never tried to use close to hot loads. In fact I've went in the other direction the last 5 or so years and downloaded other carts. But I see no reason or benefit, to me anyway to download a 22-250.
I will try some different adjustments on the die and maybe buy a couple different boxes of factory ammo

but if it's going to be of no use to me, I'm not sure I need the grief. I have a 22-250 Rem 700 HB that shoots great, just wanted to try a lighter rifle. I've thought of putting a different barrel on the 700 which would probably be the smarter way to go. Handis are Handy but like any tool, if it doesn't work properly or get the job done it's pretty much useless.
I don't have a shell holder per say as I've loaded on my Dillon since about 1980 and use Redding dies so I'm hoping that is not the problem here. It never has been in the past and I don't think the Dillon is wore out.
I believe you may be on with it being a headspace problem. When I get some inside time I'll get my polish and some stronger glasses and some tools and get into this puppy. Or just shoot what works and enjoy it.
gcrank1, Hope you don't take this wrong but you've been thinking I am overloading and trying to get the most velocity out of this gun as possible from the start of this problem last year. I am not. I think by reading some of your posts over the last couple years, you do have more experience with guns and reloading than I. I mean no disrespect and appreciate your input. I generally re read everything several times and try to look at it in different ways and see if I missed something. This in mind it can almost only be a couple of different possibilities. I hope I figure it out as I like the gun.