Ok, so I did load three dummy rounds at 1.240" COL so that I could test how much force it would take to push the bullet further into the case. I used a bathroom scale and pushed a bullet down on it (between two pieces of wood). I couldn't push hard enough to make the bullet move. So I got a channel locks and, using the scale to measure force, I put the cartridge in the pliers, squeezed the pliers by pushing the one handle squarely into the scale. The pliers gave me a force multiplier of at least 10x - I forgot to measure the lengths of each lever - and no attempt to measure the friction of the pliers pin. But the bullet didn't slip in the brass until I reached about 37 lbs. So I figure it takes something like 350 to 400 lbs. to push the bullet out of the brass. Sounds pretty excessive to me.
F. Guffey, does sound like half sizing would not decrease the brass diameter as much at the mouth as full sizing will do. That would hopefully eliminate the bulging brass. I'll try that.
I did shoot six rounds that I pressed down to 1.240 COL. I chrono'ed these, and was getting a very consistent 840 fps. Fast enough. Actually faster than I had expected, but good info. I'll load some at .1, .2 and .3 grains less to see what their speeds are, but I'd like to shoot about 850.
However, I had a totally new issue surface. The primer and the back of the brass had a big scuff mark across them - about as wide as the primer. Not deep, but a definitely visible with the naked eye scuff mark. Any ideas on what is causing this and how to fix it?