Lubri-Sizer: What is it and why do I need it?

Sizing isn't totally manditory but it does give consistency which can be important. It also gives you the option of casting an over-sized bullet and then experimenting with the final diameter a couple thou to find what works best.

I'm not really sure how often they sized bullets back in the day either but I do know that many guns came with a mold when purchased. I can't imagine a target shooter leaving this variable to chance but at the same time keeping your casting temp and alloy consistent enough to always cast bullets the same diameter is a bit of a trick.
 
I've read that slugging the barrel is a good way to gauge the sizer you will need. In a rifle, the diameter of the bore 2 inches ahead of the throat is usually the most conducive size for sizing lead bullets for accuracy. At the least its a good size to start with. Start slugging from the breach end always when determining this dimension.
 
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