You experts will probably think this is a stupid question. Oh well, here goes. I shoot a variety of 35 Whelen reloads in a mauser bolt gun chambered for 35 Whelen Improved. I use Remington factory 35 Whelen brass. Accuracy is very good. (Frankly, it's better than when I load and shoot improved rounds.) All outward signs indicate no problems. Am I missing something internally? Headspace, pressure, anyting else? The basic question here is: Is it safe to shoot "standard" loads in a AI chamber? Thanks.

yes, it is safe to shoot standard loads in an AI rifle. That is one of the beauties of such a set up.

When reloading the AI are you setting the shoulder back or just neck sizing? What bullets sre you reloading? Are you using a suitable powder for your case capacity in your AI? And lastly, seating depth (OAL) should be reviewed.

It is the only way to get AI brass. As far as I know no one offers virgin AI brass for sale.

I chambered a rifle for a friend in .25-06 AI. If I had chambered it using the AI headspace gauges, he would not have been able to merely fireform 25-06 brass because there is a difference, at least in that case/reamer. I chambered it so that a brand new, unfired Winchester case would close with a slight feel. He can now fire factory ammo without fear of excessive headspace. Not knowing how your rifle was chambered, I would have a smith who has both the Whelen and the AI version headspace gauges check it. Excessive headspace would certainly be one explaination of your lack of accuracy with your handloads. Another way to insure correct headspace is to neck new 35 Whelen brass to .375 caliber and progressively neck it back to .358 until the bolt will close with light force. This will make the case fit the chamber absolutely. The AI chambers vary with the reamer/gauge manufacturer as there is no SAMII (?) specs concerning his chamber dimensions. All are close but not like a .30-06 gauge/remaer.