Well I decided to cast some test bullets with the 3 new molds I ordered and size/lube them in my new Lyman 4500 Lubesizer. All were Lee 6 cavity moulds (.38 Cal 105 gr SWC)(.40 cal 175 gr TC)(.45 cal 200 gr SWC). The 40 cal bullets would barely go into the sizing die and then needed to be hammered out. I measured the bullets with my calipers and they seemed to average around .403-.404. The sizing die measured at ,401. Anyone else have this problem or have any thoughts? Should I send it back to LEE and request that they send me a new one?

What does your gun's bore measure? Cast bullets are supposed to be .002 to .003" oversize. If your bore is dead-nuts .400" then your sizing die is too SMALL; you could shoot those bullets as-cast (but lubed).

You could also use a slightly harder alloy, which tends to drop smaller bullets. The lower the BHN (softer) the larger the bullet will cast. Semi-auto guns need at least a BHN 12 (straight wheelweights) to a BHN 14 (Lyman #2 mix). The alloy used can change the as-cast diameter by two thousandths.

Sizing down two thousandths shouldn't require all that effort. Did you think to get some sizing lube smeared around on the inside of the die if this is your first time using it? You want it lubed so the bullets have a lubricated path into it. Once the bullet lube gets smeared around by the first few bullets, the lube film should maintain itself. If you are trying to use it dry just to size only, then you will find you really want to put some case lube or other lube on the bullets. Even WD-40 would help.

Also, what alloy are you casting? Something very hard, like linotype, can max out mold fill and be harder to size.

Tried the WD40. The bullets got very stuck in the die. Had to be hammered out. The die is true 401 the bullets were approx 403-404. Took a lot of force to even get them part of the way in. No fins on the bullets, so I am thinking the mould. Going to send them 40 and 38 back to LEE. Had one oversize cavity in the 38. Disapointing.

i use lee sizing dies and have sized .314 hard cast bullets (4% tin, water quenched) to .308 without much effort. the dies are only about $15 and fit your reloading press...maybe you should give them a try. i also use lee 6 cavity molds and am very happy with them.

I've done exactly the same thing! I took some 100 grain .32 DEWC's and sized down for .308 plinkers in a Lee die. I can't imagine my RCBS lubrisizer would have a problem taking them down the same amount, and I don't think the Lyman is significantly different from the RCBS.

I think something else is going on here.

A very, very hard casting alloy, like high copper content babbit might cause this. Cast zinc wheel weights rather than lead might cause this? The melting point is about 787 degrees, so it's not impossible. Are the bullets coming out the correct weight?

I also seem to recall there is enough range in the sizing die plunger lifting screw to bind in the lubrisizer, in effect opposing the ram by being adjusted too high for the length of the bullet.

The only other possibility that comes to mind is the bullet return plunger is the wrong size and is binding. It should be a sliding fit.

Havent weighed them yet. But I am using a known alloy of melted cast bullets. They are definately dropping too big. The sizing die is the correct size and the bullet return plunger slides in and out properly.

the only problem I've seen was my brother was casting W/W in a lee mold and got the molt hot by not taking his time , then when he was sizing the days casting some wouldn't size down.. :eek: