I didn't want to derail the .44? thread so I want to put this in a new one. This is somewhat of an answer to my "2 questions..." thread.
The issue at hand is how to deal with the parent cartridge - in this case a .30-06 / .308 family cartridge - that has a thicker wall to it compared to the desired cartridge. The parent is also slightly tapered, where the target cartridge is a straight-walled case. In this case, a .45 Winmag.
I was able to resize an old expander die ram to expand -06 brass to the proper diameter without fireforming. The process is:
The problem I ran into when cutting the case to the desired length is that the pilot won't fit due to the thicker wall!!! The answer appears to be that neck reaming will be required BEFORE the case is trimmed to length, and a smaller pilot will be needed for the "rough cut" to length. I expect that the brass will flow slightly during this process, causing the overall length to grow slightly, therefore I am suggesting double-check of the length after the case is sized.
- Cut the parent case close to the desired length
- Use the "Full Length Expander" to remove the taper
- Measure case length; final length trim & debur if required
- Full lenth size
- Neck Ream
- Expand & seat bullet like normal
I also found that the sizing needed to be done a few times - once and there was a slight dimple ring along the outside of where the "full length expander" stopped moving. A minor issue, but it could cause some feed problems if you don't resize it. It took me about 4 passes through the full-length sizer die to get the case nice and straight.
It goes without saying that you should lube the case inside and out before doing this!
A final note - the sheer amount of brass inside this straight-walled case makes me want to do more than neck ream... I don't know how much it will make a difference, but I want to make a longer reamer to open up this super-thick converted case to be closer to the factory brass. It doesn't seem to hard, and I'm going to experiment to see how much of a change to velocity it makes.
Here's the final product - a converted .06 case next to a factory .45 Winmag case... factory case on Right and Bottom:
Here is the converted expander next to the factory expander, filed and polished up smooth. I filed the "jumps" slightly under diameter so it won't scrape the cartridge: