For the reloaders here - Hornady brass sucks.

Run it through a grendel die first. Hornady brass is a little thicker and its causing the crushing. Setting the shoulders back with the grendel die first should fix it.

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Lapua

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If I were using this in a bolt action I would definitely be using Lapua. Since it's in my AR, good chance I loose some so, starline it is.

I do have lapua for my 6.5 creedmoor.

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Lapua … that’s the only brass I use

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It's the best. , Hornady is not. Hornady brass is the reason I have a 20 Practical (223 Rem necked down to 20 caliber) instead of a 204 Ruger. My son in law has a 204. When I started loading for it, Hornady was the only brass I could find so I bought some. I was NOT impressed. I later made the 20 Practical so I could use Lapua brass and have not been disappointed.

OTOH, there are some situation where I'll settle for non-Lapua brass. When using other brass, Remington and Winchester are my last choice. I've been pleased w/ Starline, Nosler, Dogtown (Midway brand made by Nosler), PPU and Peterson. For me, Hornady is just above Rem/Win, but below everyone else. I bought some Sig brass for my 300 BO but have tried the brass yet.

The Hornaday American whitetail is consistently the lowest priced name-brand rounds, often lower than PPU, when I am buying 25-06

I have never bought it, but always found it odd that it was priced so low considering the Hornaday name

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Hornady brass sucks.

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This is widely known. Use Lapua, ADG or Peterson
I use Peterson.

Lapua or Nosler for me...buy once, cry once

I did get a bag of Hornady for my 35 Whelan only because its loaded for minute-of-vitals at 200yds.

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Y-day

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You couldn’t spell out the word yesterday?

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The hornady brass all collapsed at the shoulder. I've even had issue reloading hornady brass with 6.5 grendel. Hornady is just too soft.

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A couple ideas:
What kind of lubricant were you using? Might work in one step using a different lubricant.

Are your dies the usual type or use neck sizing bushings? Going from 6.5 to 22 is a big jump. Although Federal brass handled it, that might be too much for Hornady Necking up is a lot easier than necking down.You might need to go down in increments. The aforementioned 20 Practical is a 223 Rem necked down to 20 caliber. I use Lapua brass, Redding dies and Imperial neck sizing powder. If the brass seems "sticky" I'll use Imperial sizing wax to lubricate the neck instead. To neck down, I first use the full length die, then neck down to 20 caliber using two smaller neck sizing bushings. I also shoot a 20 VarTarg using Nosler 221 Rem Fireball necked down to 20 caliber.I neck the brass down in one step using Imperial sizing was on the neck.

As a last resort, you could try annealing the brass.

Good luck and keep us updated.

I am now remembering why I didn’t like the 6.5 Staball.

Very inconsistent. I have a AutoTrickler and it’s stupid accurate. Every round was loaded with
30.98 or 31 gr of 6.5 staball.

My S/D was almost 30.

I will say that I did not sort the bullets nor the brass for weight but it really shouldn’t make that big of a difference considering powder was very exact.

Oh well, it’s still pretty danged accurate and my longest shots this winter will only be 250-300 yds though that probably won’t happen.