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large difference in OCL

I loaded a couple hundred .45 ACP cartridges with 230gr lead RN bullets.  When I put them in the storage cases I noticed that some of them were considerably shorter than the others.  The difference is over .070.  As I loaded more cartridges I saw that about one cartridge in 15 or 20 was a "short round".  Does anyone have a solution, it's not happening on a consistent basis, only occasionally.  I can't determine the problem.   I'm loading  each one the same way and every so often I get one with the bullet seated way too low.  It was suggested that there may be a lead build-up in my die, but I would think that would cause every cartridge to be shorter, not just one  every 15-20 rounds.

I switched and loaded some .357 cartridges with 180 LFN bullets and they had a variance of .040.  The .357 don't pose a big issue since they will be used in a revolver, but the .45 ACP's pose a big problem.  When I fire my pistol with  a normal length cartridge followed by a "short round" the empty is ejected to the right and the short one is dumped to the left & no round is chambered.

Which machine are you loading on? With lead RN bullets it is common to find significant variations between bullets, as there are multiple cavities in commercial bullet molds. No two cavities are exactly the same. If loading on a Dillon 550 or 650, when setting up the bullet seating die, have a fired case in station 1 to put the same upward pressure on the toolhead as you will encounter when actually reloading. Cleaning the die is a good idea as well. Dillon dies are designed for easy disassembly and cleaning without having to unscrew the die.

I'm loading lead round nose bullets.  I've cleaned the die but still have the problem.  The seating plug doesn't change depth, and the problem is very erratic, only happening every 20 rounds or so.  It would seem to me that if the bullets were varying in length, that all loaded rounds would still be the same length. The difference would be in the length of the bullet that was inside the case.  I don't see how some bullets are being shoved way down in the case while most are loaded to the correct depth.  How can the bullets be seated to .070 difference, and have the very next round the correct OCL?  If the problem is lead bullets, I don't intend to load any more of them anyway, but would like to figure out what is causing this problem.  Additional comments & suggestions will be greatly appreciated.

 The bullet seating stem typically does not push on the nose of the bullet, it contacts a diameter on the ogive, or curve of the bullet and pushes it from there down a given amount. Where this diameter is located on the bullet varies from bullet to bullet, with more variation typically in FMJ bullets, but mold cavity to mold cavity variation in cast bullets. keep in mind that cast bullets are cast on multiple cavity molds, so no two molds are ever exactly the same.

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