oscar243 said:
Thanks for all the tips. I've been reloading for 45 years and use a RCBS single stage press. I did mike the bullets at .449-.450. The brass is Remington. I will now concentrate on the dies. Being that the .45 acp headspaces on the rim, I don't crimp or least very little.
I may not have the level of experience of some others here, but have been loading .45 ACP for just over thirty years now, and can see some of your probable causes right away.
First, your bullets are of insufficient diameter for many if not most applications. I rarely load any jacketed bullets since I began casting, but all I ever loaded mic'd at 0.451" or just a bit more. Anything less is asking for complications. Yes it is possible to load smaller bullets, but they are more problematic and just not worth the effort. You need bullets of greater diameter. My cast bullets for ACP are either .452 for revolvers, or .453 for semi autos.
Second, you are using Remington brass. For over twenty years I worked for Uncle Sam, and we were issued a lot of Remington handgun ammo, some of which was .45 ACP. Throughout that time we had a lot of ongoing problems with Remington ammo, all of which was related to their brass. A lot of the ACP ammo had splits in the cases right out of the box. A lot more of them would split upon firing.
Our agency once had to return many thousands of rounds of Remington .40 S&W because the bullets could be pressed into the cases with only very light finger pressure. The sizing seemed to be OK because they would pass the case gauge test, and chamber all right, but I believe that the brass alloy was just too soft and lacked enough spring back to properly grip the bullet. Avoid Remington brass like a social disease. To do otherwise is just asking for trouble.
Third, if you are seating and crimping in one step, you need to stop as it's just begging for trouble. I know that there are a lot of people who seat and crimp in one step and get excellent results, but in order for it to work, everything has to be adjusted just right, which in and of itself is just way too complicated for most of us. Do yourself a huge favor and get yourself a dedicated crimp die. It can be a standard seater die, but remove the seating stem, and adjust it to simply crimp the case mouth in a separate step.
For example, I cast and shoot four different 200 grain bullets in .45 ACP, because different guns prefer different bullets and loads. Whenever I change from one bullet to another, I simply adjust my seater die. Only rarely would I have to readjust my crimp die, unless loading for my tight chambered Barsto barrel. If I were seating and crimping with one die, every change in seating depth would require a change in crimping depth that would work in harmony with that OAL. TOO COMPLICATED! Yes it can be done and successfully, but it's too much work.
I would also chuck my expander mandrel in a drill and dress it down a thousandth or so, and then give it good polish with crocus cloth. Then make sure that you are not belling the case mouths too much. When I seat a bullet in an auto cartridge, I like seeing a step in the outside of the case where the case has been expanded by the seated bullet. It's all about harmony between the case ID, bullet OD, and proper crimp.
Let us know how things work out.