I draw the line where the open shell length exceeds the chamber by more than 1/8". IOW, I'd not use 2 3/4" star crimped shells in a 2 1/2" chambered 20 gauge.
Another consideration is the actual length of the fired hull. Many brands that are labeled 2 3/4" are not that long when opened. Line some up side by side sometime and look at the difference. If one is worried about that 1/8", I believe it would not be a big job to find some loads that actually opened up to about that length.
SRH
Last edited by Stan; 11/11/18 08:34 AM.