Reviving this.
I have some opinions on why accuracy would suffer if the bore is more than .020 larger , but I'd like to hear your thoughts on this. I'd like others to chime in as well.
Laminar flow of the gasses
They follow the contour of the vessel
if anything is off, not concentric, or not aligned with the bore
they will favor one side and hit the base of the bullet throwing it off as the higher velocity of the gasses overtake the bullet upon exiting
sloppy thread tolerance doesnt exactly help here neither
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the more room between bullet and bore hole
the more gas flow
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proper seating depth is important also
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However!
I have used things like a brake for a .308 on a 224 cal rifle
with no accuracy degradation
I think much of it depends on burn efficiency, caliber size, and most importantly
concenctricity of the brake to the bore
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I like and use 3 slot brakes mostly, other brakes may affect this differently, such as a radial brake
I havent tested, I just know 3 slot brakes work well and I suffer no accuracy from them