Bulged cases when shooting over-sized cast in straight walled cases

yodave

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I could never help but notice that ugly bulge on my 45-70 cases when shooting cast bullets, and also couldn't help but notice that some cases had more bulge on one side of the case then the others, obviously the bullet was not seating straight, but heck I was still getting 2.5 MOA with a 4 power scope......

So I stepped up the game and bought a single shot rolling block, went down the rabbit hole and started doing a LOT of reading, I read about black powder, short sizing dies, no sizing dies and then I stumbled onto a post about partial neck sizing, but wait, there really isn't a neck on a 45-70, or any straight walled case for that matter, so I read it, not once but twice, made some adjustments to my dies and loaded some 350 grain cast for the 1895 SBL, 8 shots landed under an inch and a half at 100 yards.......4 power scope.....it's never shot like this, no weird fliers, no split groups, just a nice round tight group........so now your wondering how??? tell us how dammit......

First thing I did was took a fired piece of brass and had a good look at it, hmmm part of my crimp is still there, the case isn't perfectly ironed out, and I need a good measurement of the inside of the case to work from, so I ran it into my belling die and slightly flared the mouth. Next I lifted my full length sizing die way up, ran the case all the way up with the ram and then screwed the die down until I just felt it touch the case, then a bit more. I removed the case and measured the inside of the case with the calipers, 0.466, from there I slowly lowered the die down until the case mouth measured 0.456, 2 thou less then my 0.458 cast bullet, I locked the die in the press and lowered the decapping assembly with the hopes I could still deprime while sizing, as luck would have it I had 2 threads to spare on the RCBS full length die.

The sizing was effortless, I used way less lube then I had needed in the past while running down to the shell holder, not knowing if this was going to work I swapped dies and but the expander die in and slowly ran a case into the die, I could still feel the expander make contact with the case, could feel that contact right to the top of the stroke, hmmm......better seat a bullet and check, always need dummy rounds with no primers, so I seat a bullet, I could feel the bullet slide into the case from the bell to the taper crimp....okay......inspected the loaded dummy round, no bulge.....just a very ###y looking loaded round, held it firm in my hand and hit down bullet first into the loading bench......crimp is holding, no bullet setback......I better load some more and actually shoot them......and so I did.......and they shot better then anything I had loaded and shot before......there is far less sizing of the case, no work hardening....my brass is going to love me and last much much longer......my cast bullet targets are worthy of hanging on the wall to admire for days to come.....for the first time in almost 30 years of pulling the handle on a rock chucker press I learnt something.......I was again the student and not the teacher.........that was cool, and only means one thing......it's my turn to teach again.....so here I am passing on this wonderful bit of information to the masses, please join in with me and lift those sizing dies on the straight walled cases, there is no need to over work that expensive brass.........
 
The other interesting part of this learning expedition was gutting the sizing die and using it to iron out the mouth flair after seating a bullet where a crimp is not required, the more I experiment with all this new info, the more I realize I may need to buy a third set of reloading dies just so I can leave them all set up for their new found tasks
 
The other interesting part of this learning expedition was gutting the sizing die and using it to iron out the mouth flair after seating a bullet where a crimp is not required, the more I experiment with all this new info, the more I realize I may need to buy a third set of reloading dies just so I can leave them all set up for their new found tasks

I know exactly what you speak of: I have 3 full sets of dies for my [1] 38-55 rifle. All the sizers and seaters are set up specifically for one bullet. :)
 
I know exactly what you speak of: I have 3 full sets of dies for my [1] 38-55 rifle. All the sizers and seaters are set up specifically for one bullet. :)

I have 5 sets of 6mm PPC and 3 sets of 6mmBR........so it wouldn't be seen as a mental illness but rather be excepted as "normal"
 
Great write up!

I think these are things that many experienced handloaders who delve into the research experiment with but certainly many never hear about.
Brass life becomes indefinitely extended and results improve.
The ASSRA forum has many who dive deep into accuracy with cast bullets and single shot rifles.

For a single shot there's no reason to crimp unless you have inconsistent ignition and in that case a change in primer or powder is probably in order. I've heard tell of some handloaders actually leaving some flair on the case mouth. The theory being automatic alignment of the bullet with the bore.
 
The other interesting part of this learning expedition was gutting the sizing die and using it to iron out the mouth flair after seating a bullet where a crimp is not required, the more I experiment with all this new info, the more I realize I may need to buy a third set of reloading dies just so I can leave them all set up for their new found tasks
I learned this the other day to while loading for cast for a 30-06, it works great! Had a spare die set and had the I wonder if moment. Also made a insert that fits the body of the seating die for a mouth expander which I couldn’t seem to find. The quarantining thing is good for one thing anyway. Going to have to try this tip on my 44, it has always bugged me a bit, thanks for sharing.
 
Hmmmm.....yoDave, thanks for listing your cast bullet size, .458. I have been struggling with what cast bullet size for 45-70 is ideal. My research here indicates that .459 is best, while another source says .460 - ..461 is best.

Most reloading manuals show .458, but my LEE bullet sizer is .457 which appears to be undersize, but LEE is rarely wrong. Thoughts?
 
Hmmmm.....yoDave, thanks for listing your cast bullet size, .458. I have been struggling with what cast bullet size for 45-70 is ideal. My research here indicates that .459 is best, while another source says .460 - ..461 is best.

Most reloading manuals show .458, but my LEE bullet sizer is .457 which appears to be undersize, but LEE is rarely wrong. Thoughts?

depends on what rifle your shooting, if it is a new lever action I can be almost certain that the barrel is 0.4565 or 0.457 and that a 0.458 cast bullet will serve you well. I've gone as big as 4 thou over, if the throat will take that much bullet diameter the barrel will make quick work of sizing the bullet back to, without slugging the bore your just grabbing at straws
 
Very cool approach. I had the same issue and found 2 solutions. One was to start the bullets using a classic Lee loader. It held the bullet with a slight slip fit to keep it aligned. Once it was started straight I'd move it to the press to finish seating and roll crimp. Obviously not an option for cast over .458. The other was to run the case into the seater until I felt the bullet just enter the case mouth then lower the ram and take the round out of the press. It would be visibly crooked so I'd straighten it by hand which is actually very easy to get close. Then finish seating and apply the crimp. It solved the bulging issue and the associated stiff chambering on the bad ones.
 
I hope people start posting their results after making the change, I'd like to know it's not only me experiencing the new found accuracy and brass life
 
Hmmmm.....yoDave, thanks for listing your cast bullet size, .458. I have been struggling with what cast bullet size for 45-70 is ideal. My research here indicates that .459 is best, while another source says .460 - ..461 is best.

Most reloading manuals show .458, but my LEE bullet sizer is .457 which appears to be undersize, but LEE is rarely wrong. Thoughts?

Lee is wrong in this case, I ended up buying this custom one

https://www.trackofthewolf.com/Categories/PartDetail.aspx/1193/1/LEE-SIZE-459
 
Huh! Well damn. Learn something new every day. And I thought it was just me getting bulged cases. They always fed and shot ok. Never thought about it too much since I don't shoot the 1895 overly often. Now I have to shop for a couple more dies so that I can play around with this. And maybe I'll shoot it more! Hey, maybe a few of those fliers had a root cause other than my flinch. Thanks for the info.
 
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