Are you speaking of Hogpatrol's suggestion of using my Forster sizing die with expander ball removed. Yes, that's wouldn't be good for the reasons you say.
I've experienced problems with Hdy dies in the past (esp. on larger, 338/.358/375/458 cases). Also cheap components, bending, breakage, etc. Pretty red plastic cases. Like their bullets. Redding, RCBS, Lee (using locking RCBS rings!!!)I wonder if the people who had problems with Hornady dies crumpling necks had the same issue. I'm too lazy to research to see if Hornady expander balls have to be positioned in this same way.
@postoakI bought some Norma cases and FL resized them with Forster sizing dies, mainly to make the mouths circular. Then I fired the loaded rounds. Today, I started resizing with the die adjusted 1/4 turn past touching the shellholder. Holy cow, I've never had to use so much force to get the case into and out of the die. (I used graphite inside the neck, and Imperial Sizing Wax on the outside of the case. The shoulders were not set back at all but there was a bright ring on the shoulder where it meets the neck. (These were not super high pressure loads, BTW). The case length increased to .020 - .025 inches over maximum. Finally, on one especially difficult case the neck collapsed about 2/3rds of the way down. I think I'll probably have to toss these cases. Anyway, I removed the decapper/expander ball and sized a case and there was still a lot of pressure required, although not as much, and the ring at the front of the shoulder remained. The ID of the necks were .275. The expander ball measures .284 inch. The case wall thickness is .015", which seems about right.
I feel like we have discussed a similar problem on a different caliber but can't remember how that was resolved. My first thought was to buy a Lee collet style neck sizing die but this is a special order and Lee is so busy they have suspended special order work, so that is out.
Any thoughts? Should I get Forster involved?
@postoakI'll be contacting Forster later this morning. I'll probably wind up buying their bushing-bump die. I don't like the idea of those as much as the Lee Collet die, OTOH, it also sizes the body at the same time.
1) CBH - the dies are not new. I used them on the 100 new cases I had purchased to true up the mouths. (I wish I could remember if there was excess force required when I did that, but at least I know it wasn't enough to catch my attention.)
1) Pheroze, that 1/4 turn past the stop is getting me NO set back.
2) I agree Bruce, .275 sounds way too small to me, or at least way more than I like. I think those old posts I vaguely recall involved Hornady dies that oversized the neck.
One possibility that occurred to me is that I have an oversized chamber, but I just measured and the dies are reducing the bulge in front of the web just .003" and reducing the shoulder diameter .007". Neither of these seem excessive to me.
@postoakI wonder if the people who had problems with Hornady dies crumpling necks had the same issue. I'm too lazy to research to see if Hornady expander balls have to be positioned in this same way.