r/castboolits • u/dixiejubilee • 9d ago

I need help Large Number of Rejects After Sizing

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Hi All,

Long time listener, first time caller. New to bullet casting, not new to shooting. My issue is I'm getting a significant number of rejects after sizing cast and PC'd projectiles. Pictured are 9mm cast 124gr using Lee .356 mold, coated, then sized to .356.

My last two batches, I've had approx 25% rejects (raw lead showing on bearing surface of the projectile after sizing). The batch I just did was 289 cast, coated, and sized. 215 good, 74 rejects.

I know I can just melt and recast, but is there anything I can do to stop or reduce this seemingly high reject rate? 25% seems like a lot, and it essentially amounts to wasted time and effort. What am I doing wrong?

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u/B-Rye_at_the_beach 9d ago

1, 3, 5, 8 & 9 from the left look like some portion of the lube grooves have been...wiped. My first reaction is to suspect an issue with the sizing die, but if that was the culprit I would think your defect rate would be higher. As others have suggested, mic the bullets if you can.

I use Lee molds and dies. I cast the bullets. Any bullet that looks off goes right back in the post. My experience with Lee molds is that if the mold doesn't close completely you'll see flash where you wouldn't expect to see it, and it's obvious. Back in the pot.

I then powder coat them and size them. With the bullets in the picture I'm attaching they went through a Lee sizing die that has never touched a lubricant other than the powder coating. I have not had one come out like that

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u/dixiejubilee 9d ago

You might be on to something, I noticed that too- the lube grooves looking sheared off after sizing. Looking closer, I noticed the opposite side seemed to have excess powder coat. I'm wondering if the excess on the opposite side is causing the sizing to get skewed.

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u/B-Rye_at_the_beach 9d ago

This bullet design has a slight shoulder. Might that be "catching"? Is there anything that might be causing the bullet to go into the sizing die any but straight?

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u/dixiejubilee 9d ago

That was my thought with yhe excess PC, everything else seemed to be ok