Having trouble loading 40 cal. Started trying to load 175 gr. lead with HI TECK coating. Switched to 155 gr copper coated. Finally got rcbs die seating and crimp to just nearly fit but have run all threw the bulge buster and it will not size where the will fit. Am very disgusted with the whole process, but not going to give up. Need expert help? Thanks
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bulge buster for 40 cal
- Thread starter dwest
- Start date
Welcome to the forum.
Are you using the Lee Carbide Factory Crimp Die? It should force the rounds down to standard fit. It's the die that works with the Lee Bulge Buster.
The Bulge Buster is to get pregnant looking empty cases down to size, but using the CFCD for seating should correct the diameter of a finished round. If that is failing, it could be the coating on the bullets is too thick and elastic so the case is springing back out too wide. I have also seen some foreign brass that was too thick to work with our normal bullet sizes and wouldn't chamber afterward.
Your first diagnostic step is to measure the OD of your bullets. They should not exceed 0.4025".
Next, run the empty cases through the bulge buster, then resize them normally and see if they drop into the chamber OK. IF not and the brass is R-P, it's become work-hardened and is too springy to resize properly.
If that passes, seat a bullet using the Lee CFCD. Afterward, measure the OD of the case about 0.050" below the mouth with the seated bullet underneath it. The diameter should not exceed 0.4231" at that point, but 0.424" is usually functional (just barely). The diameter of the loaded cartridge case should not exceed 0.424" at a point 0.2" forward of the bottom of the case head.
If it is bigger, there is a sizing issue. Either the die is the wrong one or the brass too elastic or too thick, as I suggested before. If the bullets were too big, running them through a sizing die to narrow them before loading is about the only thing I can think to do. Lee makes a press mount bullet sizing kit for 0.401" diameter.
Are you using the Lee Carbide Factory Crimp Die? It should force the rounds down to standard fit. It's the die that works with the Lee Bulge Buster.
The Bulge Buster is to get pregnant looking empty cases down to size, but using the CFCD for seating should correct the diameter of a finished round. If that is failing, it could be the coating on the bullets is too thick and elastic so the case is springing back out too wide. I have also seen some foreign brass that was too thick to work with our normal bullet sizes and wouldn't chamber afterward.
Your first diagnostic step is to measure the OD of your bullets. They should not exceed 0.4025".
Next, run the empty cases through the bulge buster, then resize them normally and see if they drop into the chamber OK. IF not and the brass is R-P, it's become work-hardened and is too springy to resize properly.
If that passes, seat a bullet using the Lee CFCD. Afterward, measure the OD of the case about 0.050" below the mouth with the seated bullet underneath it. The diameter should not exceed 0.4231" at that point, but 0.424" is usually functional (just barely). The diameter of the loaded cartridge case should not exceed 0.424" at a point 0.2" forward of the bottom of the case head.
If it is bigger, there is a sizing issue. Either the die is the wrong one or the brass too elastic or too thick, as I suggested before. If the bullets were too big, running them through a sizing die to narrow them before loading is about the only thing I can think to do. Lee makes a press mount bullet sizing kit for 0.401" diameter.
bulge buster
O D of bullets
Lead with hi-teck coating =.405
Copper plated round nose=.401
Case OD
.424 Will not fit flush in case gage
After resizing with RCBS full length die .419 (fits perfect in case gage)
After loading powder and seating bullet .423
After running threw bulge buster .423
I just loaded this round and it's the best I have done.
Maybe keep tweaking.
Bulge buster does nothing
O D of bullets
Lead with hi-teck coating =.405
Copper plated round nose=.401
Case OD
.424 Will not fit flush in case gage
After resizing with RCBS full length die .419 (fits perfect in case gage)
After loading powder and seating bullet .423
After running threw bulge buster .423
I just loaded this round and it's the best I have done.
Maybe keep tweaking.
Bulge buster does nothing
A finished round of .423 diameter at the case mouth should fit fully into a SAAMI chamber if the bullet is seated deep enough. The .401" diameter bullets should give no problems if seated to a suitable overall length. However, a bullet diameter of .405" is rather large, and may interfere with the case gauge as well as the barrel chamber. Do finished rounds using either bullet fit into the barrel?
The Bulge Buster is intended for use on empty brass that has been fired in a gun with a loose or partially unsupported chamber (resulting in a case bulge). Once brass has been pushed through it, the brass may still require normal sizing before bullet seating. Unless the reloaded brass is fired again in a loose or partially unsupported chamber, it shouldn't need the bulge buster again.
I'd guess your issues are related to bullet diameter or bullet seating depth (cartridge overall length).
Edit: Another possibility could be case internal taper. In that case, the base of a longer bullet can create a slight bulge in the case due to internal case taper (internal case diameter is less as you go deeper in the case). You might check the case diameter at the approximate point where the bullet base resides in the case. If over .423" that could be the issue.
The Bulge Buster is intended for use on empty brass that has been fired in a gun with a loose or partially unsupported chamber (resulting in a case bulge). Once brass has been pushed through it, the brass may still require normal sizing before bullet seating. Unless the reloaded brass is fired again in a loose or partially unsupported chamber, it shouldn't need the bulge buster again.
I'd guess your issues are related to bullet diameter or bullet seating depth (cartridge overall length).
Edit: Another possibility could be case internal taper. In that case, the base of a longer bullet can create a slight bulge in the case due to internal case taper (internal case diameter is less as you go deeper in the case). You might check the case diameter at the approximate point where the bullet base resides in the case. If over .423" that could be the issue.
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I started reloading 40 s&w after picking up enough brass off the ground I just had to have one it was a S&W all steel double action only I was not happy I gave it to my boy .
Now years later I have Two Glocks one H&K and a berretta all shooting 180gr cast bullets and cases picked up off the ground . Then I find out you can't shoot cast bullets out of a Glock no trouble for the last 20 years .
I buy a Wilson pistol gage and none of my loads fit all the way in I check my loads in all 4 of my pistol chambers and they all fit fine it I had to find out why.
I found out case bulge happens so far down on the case that the shell holder won't let the sizing die go down that far and the case needs to be pushed all the way through the bulge buster die .
Now years later I have Two Glocks one H&K and a berretta all shooting 180gr cast bullets and cases picked up off the ground . Then I find out you can't shoot cast bullets out of a Glock no trouble for the last 20 years .
I buy a Wilson pistol gage and none of my loads fit all the way in I check my loads in all 4 of my pistol chambers and they all fit fine it I had to find out why.
I found out case bulge happens so far down on the case that the shell holder won't let the sizing die go down that far and the case needs to be pushed all the way through the bulge buster die .
bulge
After loading several rounds I got a little better. Some of the loads would not got down in the case gage like I thought they should and others would go down but not near flush. I decided to do as BBARN suggested and tried them in my Glock 22 barrel. Most all fit just fine, a few would load with a little pressure so I am guessing they will be ok on firing line.
thanks to all for the great help.I feel much better about shooting my glocks. Thanks again,.dwest
After loading several rounds I got a little better. Some of the loads would not got down in the case gage like I thought they should and others would go down but not near flush. I decided to do as BBARN suggested and tried them in my Glock 22 barrel. Most all fit just fine, a few would load with a little pressure so I am guessing they will be ok on firing line.
thanks to all for the great help.I feel much better about shooting my glocks. Thanks again,.dwest
Welcome to TFL.
Hope you got this straightened out.
Just to give some info from my experience:
I don't load 40 S&W; but I load 10mm Auto. The two use the same dies.
I bulge bust with the Lee unit. I seat with an RCBS. And I final crimp with a Lee FCD (I actually have two - one to bulge bust; and one to crimp).
My result is high quality ammo - shooting through Glocks 20sf & 29sf. The only thing different compared to what you are doing is the bullet. I use almost entirely X-treme 180 FP's, and Everglades 180 HP's. (And Speer 180 GDHP's as well as Hornady 180 XTP's - when I feel like throwing extra money downrange.)
So if I'm understanding, you and I use the same equipment (and guns, basically). What's different is the bullets.
Hope you got this straightened out.
Just to give some info from my experience:
I don't load 40 S&W; but I load 10mm Auto. The two use the same dies.
I bulge bust with the Lee unit. I seat with an RCBS. And I final crimp with a Lee FCD (I actually have two - one to bulge bust; and one to crimp).
My result is high quality ammo - shooting through Glocks 20sf & 29sf. The only thing different compared to what you are doing is the bullet. I use almost entirely X-treme 180 FP's, and Everglades 180 HP's. (And Speer 180 GDHP's as well as Hornady 180 XTP's - when I feel like throwing extra money downrange.)
So if I'm understanding, you and I use the same equipment (and guns, basically). What's different is the bullets.
I run through the Bulge Buster on empty cases when I spot an obvious bulge beforehand, but found that wasn't enough. So I started case gaging all my 40 S&W after I finish loading the rounds due to bulge issues. Those that don't pass the case gage check I run through the Lee Bulge Buster on the LEE FCD and recheck on the case gage and its extremely rare have one that will not pass the second gage check. But I will tell you that I only reload with 165 grain exclusively.
Marco Califo
New member
I load my own brass, repeatedly, for a gen 3 G23. Same brass, same gun. I do not own a bulge buster. Early Glocks had issues with not fully supported chambers, but it is my experience that Glocks made this century ( I have a G26 ~2000) have less issues. My ammo passes the barrel plunk test. I do not use maximum loads. However, I bought some new powders, and will be loading hot with Longshot soon. So my results could vary in the future
I strongly recommend a micrometer and case gauges, to troubleshoot, from a position of measuring, and knowing, what is happening, and what may be going wrong. I do not like to assume. And I do not like range pickup, if it is not from my own gun.
Another possible downside of some Glocks is my G23 plastic front site came off during requalification. I borrowed a range gun and still qualified. They also come in steel sights. So mine is going to be shipped to Glockmeister for night sites and updates like recoil assemblies and extended slide locks, etc.
I strongly recommend a micrometer and case gauges, to troubleshoot, from a position of measuring, and knowing, what is happening, and what may be going wrong. I do not like to assume. And I do not like range pickup, if it is not from my own gun.
Another possible downside of some Glocks is my G23 plastic front site came off during requalification. I borrowed a range gun and still qualified. They also come in steel sights. So mine is going to be shipped to Glockmeister for night sites and updates like recoil assemblies and extended slide locks, etc.
Doublehelix3216
New member
I have tried several different solutions for .40 bulged brass as well:
1) EGW U-Die sizing die (undersized)
2) Redding G-Rx bulge buster die
3) Lee FCD
Here are *my* results (your mileage may differ):
1) The U-die by itself did not do enough on its own, and is very difficult to use without case lube. The cases get stuck in there a lot, even if the brass has been pre-processed by the Redding G-Rx.
2) The Redding G-Rx seems to be the ticket to getting all of the brass to pass the gauge and pass the plunk test for me. I am assuming that the G-Rx is similar to the Lee Bulge Buster, but I am not 100% sure on that. The G-Rx is a pain in the butt to use since each case has to be processed individually, and takes forever. Sort of defeats the purpose of having a progressive press for reloading. NOTE: I shoot a LOT of .40 each year for USPSA.
3) I find that the G-Rx works fine alone without the U-Die, so I have gone back to a standard sizing die, and all is good.
4) I found that the Lee FCD was squashing my coated lead bullets too much, so I went back to a stadard taper crimp die, and this made a huge difference towards improving the accuracy of my coated lead projectiles, and yet the cartridges still passed all the gauge and plunk tests.
My personal conclusions: The Redding G-Rx seems to be the golden ticket for getting 40 cartridges to pass the plunk test, but is a total pain in the butt to use. I absolutely hate it.
The EGW U-Die does not seem to help pass the plunk test, and is very difficult to use on a progressive press, the cases stick a lot.
The Lee FCD over-crimps my coated lead, but with a standard taper crimp die, my cartridges pass the plunk test.
I test 100% of my completed cartridges in the Hundo case gauge.
Like I said, YMMV.
1) EGW U-Die sizing die (undersized)
2) Redding G-Rx bulge buster die
3) Lee FCD
Here are *my* results (your mileage may differ):
1) The U-die by itself did not do enough on its own, and is very difficult to use without case lube. The cases get stuck in there a lot, even if the brass has been pre-processed by the Redding G-Rx.
2) The Redding G-Rx seems to be the ticket to getting all of the brass to pass the gauge and pass the plunk test for me. I am assuming that the G-Rx is similar to the Lee Bulge Buster, but I am not 100% sure on that. The G-Rx is a pain in the butt to use since each case has to be processed individually, and takes forever. Sort of defeats the purpose of having a progressive press for reloading. NOTE: I shoot a LOT of .40 each year for USPSA.
3) I find that the G-Rx works fine alone without the U-Die, so I have gone back to a standard sizing die, and all is good.
4) I found that the Lee FCD was squashing my coated lead bullets too much, so I went back to a stadard taper crimp die, and this made a huge difference towards improving the accuracy of my coated lead projectiles, and yet the cartridges still passed all the gauge and plunk tests.
My personal conclusions: The Redding G-Rx seems to be the golden ticket for getting 40 cartridges to pass the plunk test, but is a total pain in the butt to use. I absolutely hate it.
The EGW U-Die does not seem to help pass the plunk test, and is very difficult to use on a progressive press, the cases stick a lot.
The Lee FCD over-crimps my coated lead, but with a standard taper crimp die, my cartridges pass the plunk test.
I test 100% of my completed cartridges in the Hundo case gauge.
Like I said, YMMV.
I found out case bulge happens so far down on the case that the shell holder won't let the sizing die go down that far and the case needs to be pushed all the way through the bulge buster die .
Correct.
I guess I've been lucky - my Glock 35 gen 4 .40 S&W and my hi point carbine has never had a problem chambering any of my reloads and I'm well over 10000 rounds in, about 3/5ths of that being cast lead bullets.
I can say that I typically cull out brass coming in from south of the border because I find Aguila tolerances to be dismal - came across far too many non-centered primer holes
I prefer remington and federal brass and use winchester for much of my plinking ammo -
I keep a collection of bad brass and when I discovered most of my split cases were Blazer, I stopped using those as well - I suspect an inferior alloy.
What brass are you finding most of your bulges in? Also - do you have a lot of shooters using used Gen 3 or earlier law enforcement surplus glocks? Those were bad for case bulge.
I can say that I typically cull out brass coming in from south of the border because I find Aguila tolerances to be dismal - came across far too many non-centered primer holes
I prefer remington and federal brass and use winchester for much of my plinking ammo -
I keep a collection of bad brass and when I discovered most of my split cases were Blazer, I stopped using those as well - I suspect an inferior alloy.
What brass are you finding most of your bulges in? Also - do you have a lot of shooters using used Gen 3 or earlier law enforcement surplus glocks? Those were bad for case bulge.
Welcome.
Your post is very confusing...something is grossly misspelling your words. You have to look before posting, just a little bit.
What die set and press are you using? RCBS? Lee? Mix?
What case gage are you using?
I have reloaded 1000's of 40 s&w over 20 years. I as well as many others here can probably help you get to safe and functional in a Glock 22.
Looks like you may be happy with current result....
BTW, I've never used a bulge buster, all my brass is range pick up, but I do cull a few every round of reloading.
Your post is very confusing...something is grossly misspelling your words. You have to look before posting, just a little bit.
What die set and press are you using? RCBS? Lee? Mix?
What case gage are you using?
I have reloaded 1000's of 40 s&w over 20 years. I as well as many others here can probably help you get to safe and functional in a Glock 22.
Looks like you may be happy with current result....
BTW, I've never used a bulge buster, all my brass is range pick up, but I do cull a few every round of reloading.
Is your bullet profile truncated cone? When I have a gauging problem that defies the usual adjustments, it has come down to the bullet ogive. On my revolvers, I can use those bullets if I trim the cases .010 shorter. I am big into truncated cone, partly due to my cowboy shooting, but all my 40 S&W is TCFP. None of it is lead, but I suppose it could be. I just have a couple thousand bullets from 10 or so years ago, setting my pistols aside for revolvers. My Glock 22 is my bedroom gun, which I rarely shoot at the range.
J.G. Terry
New member
Order of dies
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