Well I couldn't stand it any more, so I whipped out the old angle grinder and sawzall. Figuring I had nothing to lose and with a lot of free time on my hands lately, I beveled and polished the sharp edges on the ejector, similar to the way some folks tune the 1911 extractor in case you're familiar them.
The red line shows where I lightly rounded and polished the front part of the ejector. The yellow circle is where I beveled and polished the part of the ejector that helps hold the case against the bolt face. That part of the ejector formed a 90 degree angle and was fairly sharp, and seemed to be where the case rims were hanging up. Although hard to see, I added a 45 degree angle to the bottom 1/4 to 1/3 of the that part and then lightly smoothed the corners with a rubber polishing bit. The green arrow shows where I also added a slight bevel to that portion the ejector on the bottom edge facing the bolt face. One other place I noticed that was very sharp is the bottom left corner of the bolt face, highlighted in blue. I also lightly hit that with an India stone and rubber polishing bit.
I took off a very minimal amount of metal - key word is minimal. I've tested the modded ejector with everything I can find from snap caps, 44 Special and 44 Magnum. After this little bit of work, rounds feed much smoother now regardless of whether I cycle the lever gently or with a lot of gusto. If I notice any resistance, I just add little more pressure to the lever and the round pops into place. Before, I had to double cycle the lever to get a sticky round to feed.
As usual, YMMV, etc, etc.
Pete
