I've resized and reloaded a bunch of .40 brass with bulges without any issues. I check them visually and in a lyman cartridge gauge when I'm done loading them up. I have seen a few that had pretty big bulges though which I have tossed in the scrap bucket. I have two 5 gallon buckets of .40 brass though, so why take chances?
'When bad men combine, the good must associate; else they will fall, one by one, an unpitied sacrifice in a contemptible struggle' --Edmund Burke.
Rudy Project USA IDPA squad