You can apparently form all Of the AI cartridges except the 25-35 AI by fireforming factory ammo. That method does not work with the 25-35 AI. I was rangemaster when my friend tried the process. 10 shots, 100 % case loss.
It's quite possible your friend's rifle was improperly chambered to the Ackley Improved version of the .25-35. A proper chambering to an Ackley Improved chamber generally requires setting the barrel back and the chamber is actually cut somewhat shorter (I'll not debate how much shorter, opinions seem to vary) than the factory chamber. If the new Ackely Improved reamer is simply run into the existing chamber without setting it back, you'll end up with excess headspace, which could certainly cause the 100% case loss you mention.
I am not insisting that this is what happened in this case, just raising the possibility it could be.
