Originally Posted by Bluescot
I then took the barrels and did a side by side comparison for a "thunk" test by loading around 25% of the rounds through both of them. All the rounds "thunk" in the KKM and about 90% of the 25% rounds used in the "thunk" test failed in the Lone Wolf barrels. They would feed down about 2/3 of the way and then hang up.
All the cases used had been shot in one of two Sig .40's.
Did you try any of the resized cases in the chamber BEFORE you seated the bullet?
It could very well be that the area near the base of the bullet wasn't sufficiently resized even though you had the die all the way down. That's the reason that a lot of folks use the Lee sizing die instead of almost anything else (including the far more feature laden Dillon).
Crimping a cartridge that headspaces on the case mouth is not the best way to load. All you want to do is close up the mouth, not indent the bullet in any way.
There is also a possibility that the FCD will resize the bullet and lead bullets are deliberately 0.001" larger than jacketed. I have never used this die but if the effect is to size the loaded round to match a factory jacketed round, the bullet is now too small.
Measurements, measurements, measurements. None of this anecdotal information is useful without measurements. Diameter just above the base, diameter at the case mouth, OAL, etc. You can mark the loaded round with a Sharpie and spin it in the chamber to mark where the round is dragging. It matters whether it is dragging at the case mouth or at the base. Especially since the extra crimp operation might have bulged the case in the area of the crimp.
Did the failing rounds fit a case gauge? Sure, they fit another barrel but did they fit a gauge?