For anyone interested...here's another reason that chamber length plug gauges leading end should be significantly larger than the bullet diameter. On this reamer print, the circled area is the tapered area ahead of the case neck that leads to the beginning of the leade/free bore section. As you can see, this tapered area is .0117 long (1.520-1.5317= .0117). I have some prints here showing a .025 tapered section.
With tolerance stacking and normal reamer tolerances (usually .005 on length), it's entirely possible for a small gauge plug to be up into the tapered area and
not at the end of the neck area of the chamber (the .332 dimension in the circled area).
If you've got a $69.95 Teslong bore scope, you can close the bolt on a case in the chamber and come in from the front of the barrel and actually visualize the gap between the end of the case neck and the end of the chamber neck. If you've got a shorter bore scope like a Hawkeye, just drill the primer pocket open to let the bore scope in and look at it that way.
Not sure if the O.P. is still monitoring this or has found the issue. Hopefully he is because not getting to the root of what's going on is the first step down a potentially nasty trail of tears.
There's a fair number of 'long necked' 30BR reamers out there that are meant to be fire formed in a 6BR barrel with the neck opened up to .330-.332. This leaves the case neck around 1.545-ish long....which may be exactly what the O.P. has. Many of these reamers were sold as '30BR Robinett' reamers...which they most certainly
are not. In this scenario, unless the person doing the chambering and the end user know exactly how to come up with the long necked cases, they are going to end up with from .025-.045-ish of
chamber neck diameter free bore. This will
guarantee extremely poor accuracy and have the poor owner chasing his tail to find the cause.
Good shootin' -Al