A couple of observations
Starting to reload again.I've reloaded shells several times with out checking case length and never had a problem in my AR.Bought some once fired miltary brass and started checking case length.The cases varied quite abit.Took the longest case,resized it and dropped it in the barrel.It seated all the way in.Doe,s the military have a different case length than commertial,or is a 556 chamber different than 223?
You don't mention using a case guage, a much better check than dropping a case or cartridge in a chamber. Case guages are very inexpensive, and allow you to check resizing, base to shoulder, and over all length. Gauges for pistol calibers will also confirm MAX OAL of the reloaded cartridge. Most case guages have MAX/MIN steps cut in each end of the guage so you can visually check lengths. Using a case guage is the best method for adjusting your sizing die. Besides headspace/safety concerns, this is especially important when reloading ammo that will be used in more than one firearm, or in semi-autos. The case guage is an important quality control tool that should be during used in the reloading process to make sure that nothing has come out of adjustment while running a batch.
Everyone has their own way of doing things, much of which depends on the intended use for the ammo. Bench rest or bullseye shooters have a whole different set of expectations for their reloads than someone shooting, say, a 1919. If you check the accuracy requirements for military Ball ammo you will see that this ammo even at spec will not satisy the needs of target shooters. The specs are a compromise between accuracy, function, manufacturing tolerances, and yes, cost. This is why the milltary loads or acquires "match" ammo for competition.
I "trim to length" every time I resize. I used to do this with a Lee hand tool and later with a Lee Zip Trimmer, both work well and are inexpensive. I graduated to a Dillon 1200 power trimmer/sizer much more satisfactory for high volume shooters. Some would consider this overkill, but I rarely experience problems that can be traced to reloaded ammo.
Most manuals recommend reducing charges in military cases anywhere from 5 to 10% to compensate for reduced interior volume due to thicker case walls I usually take the MAX charge for a propellant/projectile combination militiply by .90 and compare it to the MIN charge weight, if less than the MIN I go with the MIN shown weight as long as there is a difference of 5 to 10% below the MAX charge weight.
I have had very good results using military cases, both 5.56 and .30'06 and consider them, for my purposes, the best choice.