thinking back on this some more the whole reason I had to expanf with a mandral in the first placewas because the original expander in the 444 marlin dies was way to big to just open up the 30-06 case and would crush it. I had to open the mouth sligtly to get the expader started. other than that it would have formed brass as is but with a hour glass area past were the bullet was seated.Yeah that "over expanding" part of the expanding die is what I'm talking about - cut that point back closer to the threads so the tip of the expander can reach deeper into the cartridge to open it up deeper.
I agree 100% this will allow barrels to be custom made for specific bullets by adjusting the leed.Yep, one of the things we need to decide on is the length of the case. I also think that it would be best to cut the chamber and throat in two different operations. I was looking at Clymer yesterday and they don't show a throater for the 44 mag. So everything might need to be special made.
I saw .430 throaters some were and they were only like $30. i think they use them in forcing cones and cylinders on revolvers. they must be avaliable as guys play with .44 rifles a lot.
a simple inside neck turning would take care of this should it a rise. I persoanly plan to use Reminton brass as I have a few boxes to play with. However before I were to buy a reamer I would definatly want to try a buch of differant cases and see what has the thickest cases and try to design around that I would also be open to input before ordering a reamer. Commercial cases make the most sense to me because they allow the most case capacty. HOWEVER the thicker the neck for head spacing the better. Is there any cheap military 30-06 once fired brass out there for sale??? I know there is a lot of 308 stuff and it should be considerd for use as well but will likely require aneailng.Looking at the 45acp at the mouth there is only .001 clearence and .003 at the base. Like you said just switching to Mil-spec cases might result in a round not chambering.