Case head separation is usually caused by too much headspace (and is not necessarily to overpressure).
The key word is "usually". However, not ALWAYS. Further head separation can be caused by an improper chamber that has nothing to do with headspace.
Too much headspace would make the round easy to chamber. A tight neck or short chamber/throat would make a round stiff to chamber.
Given that the bolt will close on a go gauge and not close on a no-go gauge. It is highly unlikely that headspace is the issue. This could be confirmed by shimming the bolt face a few thousandths and chambering go gauge. Typically there is less than 0.010" difference or less between a go gauge and a no-go gauge. I would shim the bolt face 0.010" - 0.012" and see if I could still close the bolt on a go gauge. If so then I would
start to suspect a defective gauge. However, I have never seen a defective headspace gauge... Not saying it can't or hasn't happened. just saying it would be a rare occurrence.
Given the situation with less than certain industry standards, it makes me wonder what specs factory ammo is made to.
There is NO uncertainty AT ALL regarding the specs to which either Lapua or Remington load the .338 Lapua Mag. Please see C.I.P. web site under headings TDCC (Tables of Dimensions of Cartridges and Chambers) linked above.
Brass on the bolt face can be caused simply by rubbing on the case when the bolt is closed and openned.
Agreed... Brass on the bolt face will tell you nothing unless the base of the cartridge is engraved. Since OP made no mention of the ejector pin hole being transferred to the base of the cartridge...
How much longer is a fired case when compared to an unfired case?
In the case of a head separation I doubt any meaningful data could be gained from such a measurement. Once the web is weakened to the point that a head separation can occur it is no longer possible to determine the amount of displacement within the chamber vs. the amount of displacement as a result of extraction / removal. Casting the chamber would be the only reliable measurement.
Very flattened primers are also an indication of a headspace problem.
But not necessarily... It can be a sign of over-sized primer pockets... Further once the web has been compromised and head sep. occurs, nothing meaningful can be gleaned from a flattened or cratered primer.
Headspace is THE most likely cause of case separation.
Most common to be sure.
A partial list of things, that can throw headspace measurement off, is in my last post.
Yes!!! Post #7 Line 2... Given the information available at this time... That would be the direction I would be looking!
A rifle headspace problem, and possibly the gage is faulty, indicating headspace is ok..
Possible, yes. Not as likely as a miss cut chamber... A mis-cut chamber would pass QC MUCH easier than improper headspace. Remington checks headspace on EVERY firearm. The chance of passing QC with a headspace issue then getting a bad gauge that also indicates proper headspace... Again, COULD happen. But not very likely.
Your description and understanding of head seperation, as stated, is spot on... I'm just not buying that this rifle has had 2 bad no-go gauges chambered, which allow it to pass a headspace check incorrectly TWICE.
OP, Nothing posted here is of any real value until you cast the chamber. At this point the best ANY of us can do is speculate. Once you cast the chamber take multiple measurements of the casting to insure the chamber is NOT out of round. Measure, record, rotate, repeat... I'm interested in hearing what the casting uncovers.