I got run through the wringer back in the late 90s when two friends of mine took turns owning an Accuracy International rifle in .308 Win. They discovered, as most have, that Federal Gold Medal Match performed the best including their hand loaded ammunition. So, seeing that they could just buy ammunition instead of developing new loads, they bought a bunch of the FGMM for competition.
No longer interested in reloading for this rifle, they kindly contributed that brass to my reloading career. Proceeding to resizing before loading, I promptly stuck both the first and second case in different sets of dies, learning much from these failures. I measured the once fired brass...
Significantly larger in the area above the head and soft, made this brass nearly useless for my or any other consumption. The chamber in their AI was significantly oversize and slightly ovoid. I let them know as carefully as I knew how that chamber was bad. We measured brass both new FGMM as well as the once fired brass from previous sessions. I cast the chamber. I suggested sending it back to AI requesting a new barrel. You'd thought I had suggested shooting their dogs!
No matter how awful this chamber was, the rifle was shooting and winning with spectacular regularity. Groups were tiny to say the least. The thought of replacing this barrel and taking the chance against lower performance was unthinkable! They chose to continue shooting it using new ammunition every time until they burned out the barrel.
Resizing the soft Federal brass was fruitless. I spent too much time trying to remove stuck cases from any of the commercial dies. No resizing was possible. I sent samples to both Federal and AI to inform them of these failures. Federal could have cared less, telling me what I already knew, the chamber was at fault. AI on the other hand, offered to pay to ship the rifle back to their US facility, rebarrel and pay to return the rifle. My friends vetoed that idea so I wrote to AI thanking them for their kind offer.
AR chambers are usually slightly oversize providing a little 'slop' to aid in chambering a cartridge. Resizing dies will usually handle the slight oversize of the brass. But sometimes you will find a need for SB sizing dies. Yes, there will always be those who claim to be the exception but in general, the SB can be very helpful.
Enjoy the process!
