Why is this happening?

[adrenalinejunkie]

I just finished reloading the last of my 500 .40 SW rounds, and for i'd say 10 of them, the bullet won't seat smoothly, and gets shaved by the case. If I felt it start to happen, most of the time I could use a different bullet on that case and it would work, then use that last bullet on a new case and it worked. I pushed the lever down all the way for each case I flared, so would it be different bullet thicknesses? When I didn't catch it happening though, this is what happened- probably wasted about a mag's worth of components:

[bruce381]

NOT running press handle all the way meaning you are NOT fullt exspanding the brass or bullets that vary in size?
OR some brass is shorter than others so exspander will not exspand them the same I always slightly over exspand to make up for
any brass that is short, try that.

[Bill Steele]

For some reason I can't see the pictures, so I will just guess.

Some of your brass might be a little shorter than others, these won't get belled as much which can cause shaving. Maybe set you flaring die down to the least common denominator case height.

If you are loading lead, maybe try another caster with higher standards, or again add more flare to accommodate the least common denominator bullet (thickest).

Finally, you could try adding a little more flare.

Is there an echo in here?

Have fun, good luck.

[adrenalinejunkie]

Thanks guys. Yeah I didn't take into account the shorter brass possibility. I'm running the ram all the way till it stops but some might still not be sizing fully. I even gave my flaring die about 1/8 of a turn past what the set recommendation is. What's weird is that most of them ran fine with the next bullet I used. Maybe the first bullet just sized them right so the next one would seat right. I'll try using a bit more flare next time, but 12 out of 500 rounds isn't horrible. I was able to salvage most of the primers, cases, and powder so it's not a total loss

[bruce381]

""Maybe the first bullet just sized them right so the next one would seat right""

makes pefect sense again that why i go a little more on my exspander because I had same problems years ago, now have dillion 650 and the die is set on the head so it stays the same

[Clownpuncher]

The last 2500 plated .45 I loaded I had probably 6 or 8 that did this. It was because the projectile was just a hair (.002") bigger than all the others. The weight was good, just that little bit bigger made it so I would crinkle the plating.

The shorter brass everyone else is speaking of is also a likely culprit.