From the guy who originally developed the Cowboy 45 Special:
Question: What about loading dies? Updated 12/15/06
Cowboy .45 Special is designed to use ordinary "off the shelf" dies.
Using a .45 Colt shell plate and sizing die, and expander and seat/crimp dies from a .45 ACP or autorim die set.
While any ACP/Autorim dies will work, along with a .45 Colt shell plate, the very best results to date have been achieved using Hornady New Dimension .45 caliber dies no. 546554.
Note Hornady uses the same dies for .45 Colt, ACP, Autorim, and win mag.
They produce a proper roll crimp, and use a sliding bullet guide that aids in seating even very short bullets straight.
The sizing die is also a bit larger than typical ACP dies, which provides proper bullet tension for .452-4 cast bullets, and requires less effort to size and expand.
This makes the press run smoother, and works brass less as well.
Personally, I only neck size fired cases, adjusting the sizer so it resizes the part of the brass where the bullet seats, but not the lower aspect.
Question: What dies will work?
If you already have .45 ACP dies, and don't care to get Hornady dies, your ACP dies will work, together with your .45 Colt shell plate.
BUT, there are ways to make "better" ammo by using a bit more intelligent die setup.
Since we are loading for .45 COLT chambers, which are notoriously roomy (the old SAAMI numbers are sloppy, and chambers cut to SAAMI max are prone to burnt powder blow-by) we need to think about the actual dimensions of our cases if the goal is to limit blow-by, especially at typical CAS levels.
The Cowboy .45 Special has much less blow-by at middle of the road CAS loads, but if you like em reallly light, or load with BP or subs, read on.
One way to help reduce blow-by at low velocity levels is to use a .45 COLT sizer die instead of the slightly smaller ACP sizing die.
Even better is what is known as "neck sizing" our fired brass.
When a case is fired it expands and "bounces" back part way, ending up a few thousanths bigger than "resized" brass.
Since we are working with very roomy chambers, we can leave the brass in the "as fired" state, sizing ONLY the case neck where the bullet seats, and sizing that only as much as needed to get decent neck tension on the bullet.
Typical pistol dies are designed to "full length size", but can be set up to partially resize or "neck size".
To do this, take a .45 Colt sizing die and adjust it so that the decapping pin JUST knocks out the spent primer.
Note how close the die mouth is to the shell plate.
Most often it is still going to resize more than half of the case.
Now, loosen the collet holding the decapping pin, and using a small drift, push the decapping pin about .150 below the top of the die such that only the bottom portion of the collet holds the pin, and retighten the collet.
Now adjust the die until it JUST knocks out the old primer, and note how much of the case is up inside the die.
Likely you can get the die adjusted to a point where ONLY the case mouth is resized (the area that grabs the bullet) and no further.
Now, as long as you can reliably knock out old primers and you're resizing the top .200 in. or so of the case neck, you've done all the sizing CAS brass needs.
Load a few fired, neck sized cases with your favorite bullets and make sure they chamber ok in your pistols (mine do with ease) and compare the diameter of the loaded once fired, neck sized cases to those which have been full length resized.
You'll likely see about .005 or .006 inch diameter difference at the point of the bullet base, which means when you next fire them, these neck sized rounds will seal much better during firing, leave little powder residue in the chambers, and still extract just fine.
This is especially important as we load for minimum recoil with light bullets.
Cowboy .45 Special develops more pressure than .45 Colt at a given velocity and that means LESS blow-by at modest levels, but if ya push the lower limits of velocity, it's still possible to get smoky cases.
Neck sizing with a .45 COLT sizing die will reduce the smoky cases.