And how exactly do you get exactly 25lbs of force by hand?
You dont. You apply sufficient force by feel to get the appropriate amount of crush on the neck. An experienced user can tell when the collet has maxed out against the mandrel. This allows you to compensate for variations in neck thickness, bullet dia, brass hardness, etc. If you use the cam over method, you lose this compensating feature.
BTW - Are you using the Hornady 174 gr FMJ boat tails - they could be the source of your problems.
As I mentioned before I have reduced most of my mandrels for a bit more neck tension. When seating bullets in brass that was sized in a regular sizing die, I can feel more tension compared to the collet dies. Most of my shooting is done while hunting and that ammunition gets banged around more than target work. I don't want any bullets moving in the cases.
And how exactly do you get exactly 25lbs of force by hand?
I tried this method and ended up blowing the aluminum retainer cap out. Apparently my 25lbs is a bit more than 25 lbs.
I was using several different bullets and noticed the issue on all.
Also, how are you annealing your cases? Are they consistent?
Or you bought a faulty die...I've had that happen with a couple of dies I picked up from Wholesale Sports when they were going out of business.
I measured the mandrel pin. It was what it is supposed to be.
I was referring to the cap blowing out, cap not sized properly...thats the only problem I've seen with these dies.
FWIW - The stock Lee mandrels are supposed to be 0.002 inches undersize for the nominal bullet diameter. I suppose they only need one thou to work if the bullet is of proper dia, but they add one thou extra to deal with under tolerance bullets.