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6.5x47 Lapua brass forming troubles

I am trying to neck down some 6.5x47L to 22x47. The problem I ran into is that for some reason I am getting 0.245 diameter neck, despite the fact that I use 6x47L Redding type S neck bushing die with .250 bushing in it as a final step, with the ball removed, only decapping pin in place. I ran the virgin brass in 6x47L Forster full lenght sizer, as an intermediate step. This gave me .262 diameter neck. Than I ran it into Redding bushing die, and I got this 0.245 neck. I tried to seat some bullets (75 gr Amax), but the bullet went with considerable resistance, and I could see the bulge in the neck where the bullet set. So I stopped there. I noticed tiny flare in the mouth of the neck after they came out of 6x47 full length Forste. The flare remained once I ran into final die. The diameter of that flare was .250. So what i am doing wrong?

My gunsmith gave me two loaded rounds (he has a rifle he cut the chamber with identical reamer). I fired those rounds and reloaded them using that same Redding bushing die with .250 bushing in it. The necks came out perfectly 0.250 diameter, without any flare and I loaded them without problem.

Than I took an expander ball from my old Redding 22-250 die and screwed it onto the stem of 6x47L Redding bushing die, and ran all that brass with .245 neck into it again. I ended up with .252 necks and they load beautifully, very little resistance to the bullet. But I don't want to use expander ball regularly, as it puts stress on this horrendously expensive brass.
I wonder, once the brass is fired and the necks are fireformed, perhaps there will be no need of expander ball, and the neck with size to .250, just as the brass my smith gave to me? Also, the neck diameter of loaded round with my brass is .253, and with his brass is .252 (no turn neck).
I positioned dies in the press so that the shell holder just touches the bottom of the die when the ram is upstroke. In the bushing die, I left a clearance of approx 1/16th of turn between the bushing and the stem nut.
So I am totally lost... any advise is appreciated!
 
I have seen this "flare" from Hornady 308 Match brass when I FL resize (Forster 308). German Salazar (I believe) explained this flare in one of his blogs. I may have it wrong but when you try to size too much in one step (more than .005 ish?) this flare develops. FWIW, I also have 2 bushing dies and my first bushing is .337 and then I drop to .331 and no flare anymore with brass. I have never seen a flare with my Lapua 308 brass but then it is .337 loaded while the Hornady is .332 loaded. They both shoot great BTW, and I have a huge pile of the Hornady. I don't load more than a 100 at a time so the extra step doesn't bother me. Quality over quanity for me if it works.

Maybe German will drop in and explain further.
 

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