Final follow up:

I got a call from the distributor thanking me for calling polywad. He stated he has two boxes of shells as a thank you from Polywad for me to pick up. I thanked him graciously and emphasized I didn't deserve replacement shells (I shot mine and have nothing to exchange) but I was concerned about the failure rate.

In the interim, I bought 5 cases of B&P shells and I'm going to give them a try. I shot 2 boxes thus far of their Subsound 7/8 ounce light loads and had ZERO failures. I'll have to keep shooting them and see if I prefer them over time as they have the same pressure as the 1 ounce Polywads. I'd rather have the 1 ounce load but not with the failures.