Handloading - Reloading Process

Reloading Process

The operations performed when handloading are:

• Case cleaning (optional, recommended for fired cases)
• Case inspection (Look for cracks or other defects, and discard visibly imperfect cases. Bent case mouths may be repaired during resizing.)
• Lubricate cases (Carbide dies do not require lubrication.)
• Size/Resize the case (For previously fired cases, primer is pressed out in this step with most die sets.)
• Ream or swage crimp from primer pocket (reloading military cases only), or mill the primer pocket depth using a primer pocket uniformer tool
• Measure and trim the case length (as needed; rarely required with handgun cases)
• Deburr, ream case mouth and size case neck (optional, as-needed; trimmed cases need to be deburred); some bench rest shooters also do outside neck turning at this stage, to make the cartridge case have uniform thickness so that the bullet will be released with the most uniformity
• Clean primer pocket (optional; primer pockets will have deposits from combustion) and do flash hole uniforming (optional, generally, only bench rest shooters do this)
• Expand or chamfer case mouth (not required with boattail rifle bullets)
• Clean the lubricant from the cases
• Seat a new primer (primer pockets often become loose after multiple loadings; a lack of effort being required to seat new primers indicates a loose primer pocket; cases with loose primer pockets are usually discarded, after crushing the case to prevent its reuse)
• Add a measured amount of powder (critical step; incorrect powder charges are extremely dangerous, both underweight as well as overweight)
• Seat the bullet in the case for the correct cartridge overall length (OAL) and for aligning bullet cannelure (if present) with case mouth
• Crimp the bullet in place (optional; some may hold the bullet with neck tension alone)
• Cartridge inspection

When previously fired cases are used, they must be inspected before loading. Cases that are dirty or tarnished are often polished in a tumbler to remove oxidation and allow easier inspection of the case. Cleaning in a tumbler will also clean the interior of cases, which is often considered important for handloading high-precision target rounds. Cracked necks, non-reloadable cases (steel, aluminum, or Berdan primed cases), and signs of head separation are all reasons to reject a case. Cases are measured for length, and any that are over the recommended length are trimmed down to the minimum length. Competition shooters will also sort cases by brand and weight to ensure consistency.

Removal of the primer, called decapping, is usually done with a die containing a steel pin that punches out the primer. Berdan primed cases require a different technique, either a hydraulic ram or a hook that punctures the case and levers it out from the bottom. Military cases have crimped-in primers, and decapping leaves a slight ridge that inhibits seating a new primer. A reamer or a swage is used to remove this crimp.

When a cartridge is fired, the internal pressure expands the case to fit the chamber in a process called obturation. To allow ease of chambering the cartridge when it is reloaded, the case is swaged back to size. Competition shooters, using bolt action rifles that are capable of camming a tight case into place, often resize only the neck of the cartridge, called neck sizing, as opposed to the normal full length resizing process. Neck sizing is only useful for cartridges to be re-fired in the same firearm, as the brass may be slightly oversized in some dimensions for other chambers, but the precise fit of case to chamber will allow greater consistency and therefore greater potential accuracy. Some believe that neck sizing will permit a larger number of reloads with a given case in contrast to full size resizing, although this is controversial. Semi-automatic rifles and rifles with SAAMI minimum chamber dimensions often require a special small base resizing die, that sizes further down the case than normal dies, and allows for more reliable feeding.

Once the case is sized down, the inside of the neck of the case will actually be slightly smaller than the bullet diameter. To allow the bullet to be seated, the end of the neck is slightly expanded to allow the bullet to start into the case. Boattailed bullets need very little expansion, while unjacketed lead bullets require more expansion to prevent shaving of lead when the bullet is seated.

Priming the case is the most dangerous step of the loading process, since the primers are pressure sensitive. The use of safety glasses or goggles during priming operations can provide valuable protection in the rare event that an accidental detonation takes place. Seating a Boxer primer not only places the primer in the case, it also seats the anvil of the primer down onto the priming compound, in effect arming the primer. A correctly seated primer will sit slightly below the surface of the case. A primer that protrudes from the case may cause a number of problems, including what is known as a slam fire, which is the firing of a case before the action is properly locked when chambering a round. This may either damage the gun, and/or injure the shooter. A protruding primer will also tend to hang when feeding, and the anvil will not be seated correctly so the primer may not fire when hit by the firing pin. Primer pockets may need to be cleaned with a primer pocket brush to remove deposits that prevent the primer from being properly seated. Berdan primers must also be seated carefully, and since the anvil is part of the case, the anvil must be inspected before the primer is seated. For reloading cartridges intended for use in military-surplus firearms, rifles especially, "hard" primers are most commonly used instead of commercial "soft" primers. The use of "hard" primers avoids slamfires when loading finished cartridges in the military-surplus firearm. Such primers are available to handloaders commercially.

The quantity of gunpowder is specified by weight, but almost always measured by volume, especially in larger scale operations. A powder scale is needed to determine the correct mass thrown by the powder measure, as loads are specified with a precision of 0.10 grain (6.5 mg). One grain is 1/7000 of a pound. Competition shooters will generally throw a slightly underweight charge, and use a powder trickler to add few granules of powder at a time to the charge to bring it to the exact weight desired for maximum consistency. Special care is needed when charging large capacity cases with fast burning, low volume powders. In this instance, it is possible to put two charges of powder in a case without overflowing the case, which can lead to dangerously high pressures and a significant chance of bursting the chamber of the firearm. Non-magnum revolver cartridges are the easiest to do this with, as they generally have relatively large cases, and tend to perform well with small charges of fast powders. Some powders meter (measure by volume) better than others due to the shape of each granule. When using volume to meter each charge, it is important to regularly check the charge weight on a scale throughout the process.

Competition shooters also often sort bullets by weight, often down to 0.10 grain (6.5 mg) increments. The bullet is placed in the case mouth by hand, and then seated with the press. At this point, the expanded case mouth is also sized back down. A crimp can optionally be added, either by the seating die or with a separate die. Taper crimps are used for cases that are held in the chamber by the case mouth, while roll crimps may be used for cases that headspace on a rim or on the cartridge neck. Roll crimps hold the bullet far more securely, and are preferred in situations, such as magnum revolvers, where recoil velocities are significant. A tight crimp also helps to delay the start of the bullet's motion, which can increase chamber pressures, and help develop full power from slower burning powders (see internal ballistics).