After taking a closer look, is seems that Station 2 ( on the Dillon 550 ) needs to be lowered about .005" to open the bell-mouth a tad.
Then on Station 3, the die needs to be raised a bit, then the seater plug needs to be lowered to get the OAL to 1.250".
Then on Station 4, the Lee FCD needs to be set so that is bottoms out on the shellplate, and the crimp adjustment
needs to be adjusted to fully iron-out the bell-mouth.
I have a feeling that the bell was not large enough, allowing the seater to "shave" the bullet before it was fully seated.
Then that lead is building-up right on the mouth of the shell, causing the cartridge to not enter the case gauge fully.
Like I said, I loaded this batch MANY years ago, but the ones I loaded after these have been working 99% in both
my Glock and my S/A M1911.
Prob just .015" of lead coming between a "Pass" and "Fail" on the gauge.