RMC: Looks like you and your bro gave this incident a hard look.
Even given your investigation, I still think this is an ammo problem.
In a worst case scenario, if a seriously pitted chamber area of the barrel DID LET GO, that still would not account for the indications of over-pressure on the cartridge case. One would expect that the pressure vessel would be venting the pressure even more rapidly with a fracture or vent in the chamber wall, and that the pressure would drop more rapidly than normal. Hence, how could there be MORE pressure than normal evident on the cartridge case?
Good luck in your continued investigation. I hope to learn something from this incident, as I "roll my own" also, but on a PW 375 single stage loader.