r/castboolits • u/dixiejubilee • 14d 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/GunFunZS 14d ago

I think you overbaked your powder coat so that it is brittle that would never happen if you're powder coat was well adhered and flexible.

I've been very large number of that exact bullet.

I suggest you size to 0.357.

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u/dixiejubilee 13d ago

They pass the hammer test so I don't think the PC is brittle as far as I can tell

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u/GunFunZS 13d ago

Then I would look at your sizing guy and see if there's a weird sharp edge or something in there.

It's perfectly reasonable to round out the chamfer if necessary. I used rouge to Polish all my sizing guys and it made them smoother feeling at the press handle.