Michael,
At first glance, it appears that the chuck and Operation (Op) profile are not correctly matched for the seam you're attempting to make, or there may be a mismatch between the chuck profile and the end type you're using. I agree that the profile of the end material shown in your image looks quite different from what I would expect, extending outward at a steep angle.
I've attached a resource that has been immensely helpful for us when troubleshooting seam specification issues on our Codi CCL-45. We use Ball ends and adhere to the same specifications, targeting a 0.045 in. thickness.
Adjusting the Op height relative to the chuck can influence this profile relationship and the shape of the seam pocket, though I doubt it could correct for such a drastic change in end geometry.
For testing, you can perform an Op 1-only run on the Codi by physically removing the entire Op 2 mounting block from the post (one set screw and two clamping bolts). Be sure not to lose the spacer ring above the block or the shaft key during removal.
Regarding the Op roller contacting the chuck - that's likely causing significant wear and other issues, including damage to the Op roller bearings, main chuck/drive bearings, and possible deformation of the chuck profile itself.
Do you also measure countersink depth during your seam inspections? If so, are those measurements within Ball's published specifications?
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