Oh no! The head pulled off a case. Now I’ve got a separated case in my rifle!

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This article explains how to remove a stuck case, in this instance a copper washed steel 7.62x54R case from a SVT40, using a .303BR separated case extractor.

In the hour before the club’s annual Winter Milsurp match, shooters have a few relays to check their zero. It seemed appropriate to shoot this particular SVT40 in the cold. On the 50-yd bench I wanted to fire a group and to judge the fall of shot before committing to the 100yd target. I fired a shot. Bang! The next round fed but the bolt wouldn’t close. With the rifle pointed downrange, I pulled the charging handle back but not far enough to catch a new round, and let the parts fly forward again. Same stoppage in the same place. Hmm? I ejected that round and looked into the breech. I saw the sharp edge of the fired case about ½-inch into the chamber. Remembering that gunsmithing in the cold is always a stupid idea unless your life depends on it, I put the rifle on the rack and shot the match with Plan B.

The last time I had a separated case was firing belt after 220-round belt through a tripod-mount Machine Gun 7.62 C1 in the reserves. Four ball-one tracer, disintegrating link. Oh the good old days! These were Browning 1919A4s converted from 30-06 and the C1 conversion was not as reliable as the C5 conversion. Wheeled recce crewmen were trained on many things, including machine gunnery. If the headspace was too loose, the head would pull off a fired case and the gun would be down until cleared. Shoot them a lot, the parts heat up, lubrication changes how things move, or the adjustment clicker could back out. That day, my separated casing was extracted with the next round fed and the gun was immediately back in action. The machine gun tool kit had a lever affair that I remember was hard to use.

It sounds simple, but the wise shooter’s first response should be to not panic! In machine gun classes the instructors had the phrase, use the correct tool correctly. If you lever, pick, pry or scrape away at the case with a knife or screwdriver, you are guaranteed to make things worse. You will deform the case and very likely scratch the chamber.

There are different styles of separated case tools. Most have an expander smaller than the inside neck diameter and a base that is moved from the breech area. The one I chose was for .303BR because its case head was large enough for the SVT extractor, and the others were for .30-06 and 7.62 which have smaller diameter heads. One thought in my deliberations was that Globe Firearms in Vanier (Ottawa) rechambered poor condition Finnish SVT40s to .303BR “Mohawks”. The 7.62x54R is more similar to .303BR than the US cartridges, and Globe didn’t modify the bolt faces. I’ve had these tools for years, and they stay with my other speciality tools waiting for that one time to be used that one correct way.

This case extractor has three parts; a head, a shaft, and an expander. The shaft screws to the head. The expander slides along the shaft. The expander has with three petals or fingers, each with threads that grip inside the case neck. Rearward motion of the shaft pulls the expander against a bevel which flexes the fingers and forces the threads to bite inside the neck. Elegant and simple. The USGI tools engage the mouth of the case, but work similarly.

My workflow was simple
  • Put the rifle in a firm rest with good light;
  • Lay out the tools and choose the most correct one;
  • Apply some penetrating oil to the chamber in hopes it would creep between the case and the chamber wall;
  • Confirm the tool is correctly assembled and tight, then hand seat it in the chamber;
  • Let the operating spring pressure drive the tool into the chamber. In my situation, it closed just like chambering a live round; and,
  • With a firm grip, pull the charging handle to the rear. In my situation, it opened to the primary extraction point and resisted. I took a firmer grip and pulled the charging handle completely to the rear. The tool and case ejected smoothly.
See the photos for the comparison. (The live 7.62x54R was only present for size comparison.) Unscrew the shaft from the head and remove the storied but now useless separated case. Continue with cleaning or whatever else needs to be done.

What if you don’t have the correct separated case tool? I do not approve or encourage these methods. After all, I was taught to use the correct tools correctly, and I had that tool.
  • It is possible to use the return spring velocity to force another cartridge into the separated case. In my story about the machine guns, that technique worked. Pull the parts to the rear hoping the case pulls out by friction. If it doesn’t come out after two or three tries, stop. Repeated pressure will only expand the problem harder against the chamber walls;
  • A second option, is to force an oversize phosphor bronze or stainless-steel cleaning brush in from the breech as a scraper, hoping to grip the mouth with the wires of the brush. In this situation, I’d hit a strong cleaning rod from the muzzle onto the brush. This could ruin a good brush and damage the rod’s threads, but these are consumables compared to a barrel;
  • A third thought is to force a tight-fitting patch against the case mouth and hammer or pull towards the breech;
  • If you have the right supplies, put an oiled patch as a dam in the bore and backed with a cleaning rod. With the rifle vertical, pour molten Cerrosafe chamber casting alloy into the exposed breech. When the Cerrosafe has cooled, bump the now-fused case and alloy out together. Melt the Cerrosafe for reuse. A hotter alternative is to pour a slug of molten lead into the chamber.
  • Two methods I STRONGLY DISCOURAGEdue to the risk of permanent damage.
    • Twist a tapered round file into the case getting the teeth to engage inside the neck,
    • Or, turn a thread cutting tap into the case metal.
  • In both of the above situations, drive out the tools with a cleaning rod like a slide hammer.
Your mileage may vary. It is your rifle. We learn by trying, but we also learn from others’ mistakes. What caused the author’s 7.62x54R case to fail? A combination of genuine military conditions – steel cased surplus ammunition, a dirty chamber or sticky neck, the SVT40’s inherently unpredictable gas system, or a poorly set gas plug which allowed too much gas to put too much force on the ejection cycle. The first three are within the shooter’s control, and for the latter, I have the right five-sided wrench. No excuses next outing.

What a separated case looks like.

tbc
 
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now the condensed version the cases are not stuck they come out easy
i simply take a tap insert it into the case from the breech end make sure it bites a bit take a cleaning rod insert from the muzzle give it a tap and put it comes
i have done many 99 savage and leeenfields like this
 
In my comments I discourage anyone from using steel cutting tools in chambers. Savage stopped making Model 99s a long time ago, and the Lee Enfield plants are now housing developments. My suggestions are less aggressive, and I promised the competitors at the MilSurp match to write up how I solved my problem.
 
I have the broken case extractor for the Lee Enfield which works well. Haven’t used it on mine but have for other people. Sometimes pulling a cleaning rod with a brush on it from the muzzle to chamber works. If you have a rifle you can remove the bolt from.
 
I never tried it but I have wondered if a small expanding concrete or drywall anchor bolt might work. Insert and twist to slightly expand and then extract.


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I have used a brush several times to take out a seperated case, and also have driven an ear plug into the case form the chamber end, then inserted an old brush with 5 minute epoxy putty into the case .
I then tap the case out from the muzzle end.
The one is the picture I used a spare jag to put the epoxy on.
Cat
 

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I have some long shank HSS drill bits that work great they bite into the case and get ti turning so you can pull them out, or push from muzzle, all this done by hand, easy outs with an extension welded on are even better. , last one was Remington brass in a 35 Whelen and it came out with a bronze brush. Worst are the surplus steel cases, I think they are coated with lacquer and glue themselves in the chamber.
 
Have removed a case section with a brush from the muzzle end but had to bend the brush so the tip was to the side so it hit the case mouth rim
another with a Leatherman screwdriver from the breech, but these were not really stuck hard
 
To avoid this happening, I lube my SVT chamber with light grade oil before firing. It has no ill effect on rifle operation as oil gets blown on rivelli channels with each shot and lube the bolt and chamber in the process. Yes its sooty, but cleaning it is easier after that.

OP you might want to adjust your gas setting as the more violently the rifle cycles the more likely the head separation can occur. The fine tune of the setting for winter operation is that it feeds reliably. In manual they say any temp below -5C rifle should be set at 1.5 but if it cycles on lower setting its ok to keep it as is
 
I had case head separation happen to me on my Lee Enfield. I use a Easy out, screw it in carefully to grab the brass only. Insert a cleaning rod from the muzzle end and tap it out with a mallet.
 
I have a 303 Broken case extractor because I tend to run my brass until failure. That said, in times I've forgotten it, I have had luck a few times for a stuck case to attempt to chamber the next round forcefully then extract it, bringing both the broken brass and new round out at the same time. Hasn't worked every time however, so the proper tools or other tricks are great to have
 
ive been lucky enough to never need one. ive also had lotsa case head separations on 303 . i simply ram the nexr one into what remains in the chamber, and the taper of the 303 it squeezes in, and locks in. simply pull it out and they both come out.
 
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