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{{Short description|Manual assembly of ammunition}}
{{About|metallic cartridge and shotshell handloading|construction of paper cartridges|Paper cartridge}}
{{Essay-like|date=January 2022}}
[[File:Reload Cartridge Example 3 new.jpg|thumb|Components of a modern bottleneck [[rifle]] [[cartridge.]] Top-to-bottom: Copper-jacketed [[bullet]], smokeless powder [[:wikt:granule|granule]]s, rimless brass case, [[Boxer primer]].]]
'''Handloading''', or '''reloading''', is the
The term ''handloading'' is the more general term, and refers generically to the manual assembly of ammunition
==
Some consider handloading [[Cartridge (firearms)|cartridges]] or [[Shotgun shell|shotshells]] a hobby, but reloading can save the shooter money, providing a greater quantity of higher quality ammunition within a given budget. However, hobbyists' enjoyment of the reloading process may be a significant benefit.
The opportunity to customize performance is another common goal for many handloaders. [[Hunter]]s for instance, may desire cartridges with specialized bullets with specific [[terminal ballistics|terminal performance]]. [[Shooting sports|Target shooters]] often experiment extensively with component combinations in an effort to achieve the best and most consistent bullet [[external ballistics|trajectories]], often using cartridge cases that have been [[Fire forming|fire formed]] in order to best fit the [[chamber (firearms)|chamber]] of a specific firearm.<ref>{{cite journal|title=Reloading 101 part II: starter kits |journal=Guns Magazine |date=September 2008 |author=John Taffin |url=http://findarticles.com/p/articles/mi_m0BQY/is_9_54/ai_n27963825/pg_1?tag=artBody;col1 |url-status=dead |archive-url=https://web.archive.org/web/20090203181439/http://findarticles.com/p/articles/mi_m0BQY/is_9_54/ai_n27963825/pg_1?tag=artBody%3Bcol1 |archive-date=2009-02-03 }}</ref> Shotgun enthusiasts can make specialty rounds unavailable through commercial inventories at any price.<ref>{{cite journal |title=Five Reasons to Handload Shotshells |journal=American Rifleman |date=April 2017 |author=Aaron Carter |url=https://www.americanrifleman.org/content/5-reasons-to-handload-shotshells }}</ref> Some handloaders even customize cartridges and shotshells simply to lower recoil, for instance for younger shooters who might otherwise avoid shooting sports because of the high recoil of certain firearms.<ref>{{cite journal |title=Gunpowder Selection for Controlling Recoil |journal=Shooting Sports USA |date=June 2017 |author=Brad Miller, Ph.D. |url=https://www.ssusa.org/articles/2017/6/19/gunpowder-selection-for-controlling-recoil }}</ref> It is also a not infrequent practice for handloaders to make [[overpressure ammunition|increased-power ammunition]] (i.e. "hot loads") if higher [[muzzle velocities]] (hence flatter trajectories) are desired. Rather than purchasing a special purpose rifle, which a novice or adolescent shooter might outgrow, a single rifle can be used with special handloaded rounds until such time more powerful rounds become appropriate. This use of specialized handloading techniques often provides significant cost savings as well, for instance when a hunter in a family already has a full-power rifle and a new hunter in the family wishes to learn the sport. This technique also enables hunters to use the same rifle and caliber to hunt a greater diversity of game.<ref name=rrc>{{cite book |last=Camp |first=Raymond R. |title =The New Hunter's Encyclopedia |publisher =The Stackpole Company |edition =Third |date =1966 |location =Harrisburg, Pennsylvania |pages =524–526 }}</ref>▼
Handloading ammunition avoids the [[labor costs]] of commercial [[production lines]], reducing the expenditure to only the cost of purchasing components and equipment. Reloading may not be cost effective for occasional shooters, as it takes time to [[return of capital|recoup the cost]] of needed equipment, but those who shoot more frequently will see cost-savings over time, as the brass cartridge cases and shotgun shell hulls, which are often the most expensive components, can be reused with proper maintenance. Rather than purchasing a special purpose rifle, which a novice or adolescent shooter might outgrow, a single rifle can be used with special handloaded rounds until such time more powerful rounds become appropriate. This use of specialized handloading techniques may offer significant cost savings when a hunter in a family already has a full-power rifle and a new hunter in the family wishes to learn the sport. This technique also enables hunters to use the same rifle and caliber to hunt a greater diversity of game.<ref name=rrc>{{cite book |last=Camp |first=Raymond R. |title =The New Hunter's Encyclopedia |publisher =The Stackpole Company |edition =Third |date =1966 |location =Harrisburg, Pennsylvania |pages =524–526 }}</ref>
=== Improved performance and accuracy ===
Where the most extreme accuracy is demanded, such as in rifle [[benchrest shooting]], handloading is a fundamental prerequisite for success,<ref>{{cite journal |title=Reloading Techniques for Match-Grade Loads |journal=Shooting Sports USA |date=August 2018 |author=Stanton L. Wormley, Jr. |url=https://www.ssusa.org/articles/2018/8/29/reloading-techniques-for-match-grade-loads }}</ref> but can only be done consistently accurate, once load development has been done to determine what cartridge parameters works best with a specific rifle.<ref>{{cite journal |title=Load Development Methods |website=LoadDevelopment.com |date=October 2020 |author=A.J. Deysel |url=https://www.loaddevelopment.com/load-development-methods/ }}</ref> Additionally, collectors of rare, antique and foreign-made firearms must often turn to handloading because the appropriate cartridges and shotshells are no longer commercially available. Handloaders can also create cartridges for which no commercial equivalent has ever existed — the so-called [[wildcat cartridge]]s,<ref name=nonte_14>Nonte, chapter 14, "Case Forming: Making What You Need from What You've Got."</ref> some of which can eventually acquire mainstream acceptance if the ballistic performance is proven to be good enough.<ref>{{cite journal |title=DIY Rifle Cartridges: Wildcatting Made Easy |journal=Shooting Illustrated |date=April 2019 |author=Richard Mann |url=https://www.shootingillustrated.com/articles/2019/4/10/diy-rifle-cartridges-wildcatting-made-easy }}</ref> However, as with any hobby, the pure enjoyment of the reloading process may be the most important benefit.▼
There are three aspects to [[ballistics]]: [[internal ballistics]], [[external ballistics]], and [[terminal ballistics]]. Internal ballistics refers to things that happen inside the firearm during and after firing, but before the bullet leaves the muzzle. The handloading process can realize increased accuracy and precision through improved consistency of manufacture, by selecting the optimal bullet weight and design, and tailoring bullet velocity to the purpose. Each cartridge reloaded can have each component carefully matched to the rest of the cartridges in the batch. Brass cases can be matched by volume, weight, and concentricity, bullets by weight and design, powder charges by weight, type, case filling (amount of total usable case capacity filled by charge), and packing scheme (characteristics of granule packing).<ref name=rrc/>▼
Handloading is a fundamental prerequisite for success where the most extreme accuracy is demanded, such as in rifle [[benchrest shooting]],<ref>{{cite journal |title=Reloading Techniques for Match-Grade Loads |journal=Shooting Sports USA |date=August 2018 |author=Stanton L. Wormley Jr. |url=https://www.ssusa.org/articles/2018/8/29/reloading-techniques-for-match-grade-loads }}</ref> but can only be done consistently accurately following load development to determine what cartridge components work best with a specific rifle.<ref>{{cite journal |title=Load Development Methods |website=LoadDevelopment.com |date=October 2020 |author=A.J. Deysel |url=https://www.loaddevelopment.com/load-development-methods/ }}</ref>
▲
▲There are three aspects to [[ballistics]]: [[internal ballistics]], [[external ballistics]], and [[terminal ballistics]]. Internal ballistics refers to things that happen inside the firearm during and after firing, but before the bullet leaves the muzzle. The handloading process can realize increased accuracy and precision through improved consistency of manufacture, by selecting the optimal bullet weight and design, and tailoring bullet velocity to the purpose. Each cartridge reloaded can have each component carefully matched to the rest of the cartridges in the batch. Brass cases can be matched by volume, weight, and concentricity, bullets by weight and design, powder charges by weight, type, case filling (amount of total usable case capacity filled by charge), and packing scheme (characteristics of granule packing).<ref name=rrc/>
=== Avoidance of problems with commercial ammunition ===
▲
== Equipment ==
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Shotshell presses are generally a single unit of the "H" configuration that handles all functions, dedicated to reloading just one gauge of shotshell. Shotshell reloading is similar to cartridge reloading, except that, instead of a bullet, a wad and a measure of shot are used, and after loading the shot, the shell is crimped shut. Both 6 and 8 fold crimps are in use, for paper hulls and plastic hulls, respectively. Likewise, roll crimps are in use for metallic, paper, and plastic hulls. The shotshell loader contains stations to resize the shell, measure powder, load the wad, measure shot, and crimp the shell.<ref name=shotshell>{{cite web |url=https://shop.rcbs.com/WebConnect/,DanaInfo=shop.rcbs.com+MainServlet?storeId=webconnect&catalogId=webconnect&langId=en_US&action=ProductDisplay&screenlabel=index&productId=2831&route=C04J002 |title=RCBS Products - Shotshell Reloading Presses |access-date=2007-09-14 }}{{Dead link|date=January 2020 |bot=InternetArchiveBot |fix-attempted=yes }}</ref> Due to the low cost of modern plastic shotshells, and the additional complexity of reloading fired shells, shotshell handloading is not as popular as cartridge handloading.<ref>{{cite web |url=http://www.chuckhawks.com/touching_shotshell_reloading.htm |title=Touching on Shotshell Reloading |author=Randy Wakeman |publisher=Chuck Hawks}}</ref> For example, unlike when handloading rifle and pistol cartridges, where all the various components (cases, gas checks, powder, primers, etc.) from different manufacturers are usually all interchangeable, shotshells typically are loaded for particular brands of shotshell cases (called hulls) only with one specific brand of wad, shot cup (if used), primer, and powder, further increasing the complexity and difficulty of reloading shotshells. Substitution of components is not considered safe, as changing just one component, such as a brand of primer, can increase pressures by as much as 3500 PSI, which may exceed SAAMI pressure limits. Reloading shotshells is therefore more along the lines of precisely following a recipe with non-fungible components. Where shotshell reloading remains popular, however, is for making specialized shotgun shells, such as for providing lowered recoil, when making low-cost "poppers" used for training retrievers before hunting season to acclimate hunting dogs to the sound of a gun firing without actually shooting projectiles, for achieving better shot patterning, or for providing other improvements or features not available in commercially loaded shotshells at any price, such as when handloading obsolete shotshells with brass cases for gauges of shotshells that are no longer commercially manufactured.
Rifle and pistol loading presses are usually not dedicated to reloading a single caliber of cartridge, although they can be, but are configured for reloading various cartridge calibers as needed. In contrast, shotshell presses are most often configured for reloading just one gauge of shotshell, e.g., 12 gauge, and are rarely, if ever, reconfigured for reloading other gauges of shotshells, as the cost of buying all new dies, shot bar, and powder bushing as required to switch gauges on a shotshell press often exceeds the cost of buying a new shotshell press outright, as shotshell presses typically come from the factory already set up to reload one gauge or bore of shotshell. Hence, it is common to use a dedicated shotshell press for reloading each gauge or bore of shotshell used. Likewise, the price of shot for reloading shotshells over the last several years has also risen significantly, such that lead shot that was readily available for around $0.50/lb. (c. 2005) now reaches $2.00 per pound (2013.) Due to this large increase in the price of lead shot, the economy of reloading 12 gauge shotshells vs. just using promotional (low-cost) 12 gauge shotshells only starts to make economic sense for higher volume shooters, who may shoot more than 50,000 rounds a year. In contrast, the reloading of shotshells that are usually not available in low-cost, promotional pricings, such as .410 bore, 12 ga. slugs, 16 ga, 20 ga., and 28 ga., becomes more economical to reload in much smaller quantities, perhaps within only 3-5 boxes of shells per year. Reloading .410 bore, 12 ga. slugs, 16 ga., 20 ga, and 28 ga. shells, therefore, remains relatively common, more so than the reloading of 12 gauge shotshells, for which promotional shotshells are usually readily available from many retailers. These smaller bore and gauge shotshells also require much less lead shot, further lessening the effect of the rapid rises seen in the price of lead shot. The industry change to steel shot, arising from the US and Canadian Federal bans on using lead shotshells while hunting migratory wildfowl, has also affected reloading shotshells, as the shot bar and powder bushing required on a dedicated shotshell press also must be changed for each hull type reloaded, and are different than what would be used for reloading shotshells with lead shot, further complicating the reloading of shotshells.
With the recent rampant rise in lead shot prices, though, a major change in handloading shotshells has also occurred. Namely, a transition among high volume 12 gauge shooters from loading traditional 1-1/8 oz. shot loads to 7/8 oz. shot loads
With the recent shortages over 2012–2013 of 12 gauge shotshells in the United States (among all other types of rifle and pistol ammunition), the popularity of reloading 12 gauge shotshells has seen a widespread resurgence. Field use of the International 24 gm. 12 gauge shells has proven them to be effective on small game, while stretching the number of reloads possible from a bag of shot, and they have subsequently become popular for hunting small game. Since shot shells are typically reloaded at least 5 times, although upwards of 15 times are often possible for lightly loaded shells, this transition to field use of 24 gm. loads has helped mitigate ammunition shortages for hunters.
Shotshell presses typically use a charge bar to drop precise amounts of shot and powder. Most commonly, these charge bars are fixed in their capacities, with a single charge bar rated at, say, 1-1/8 oz. of lead shot, with a switchable powder bushing that permits dropping precisely measured fixed amounts of different types of powder repetitively (e.g., MEC.) On the other hand, some charge bars are drilled to accept bushings for dropping different fixed amounts of both shot and powder (e.g. Texan.) For the ultimate in flexibility, though, universal charge bars with micrometers dropping fixed volumes of powder and shot are also available; these are able to select differing fixed amounts of both powder and shot, and are popular for handloaders who load more than just a few published recipes, or, especially, among those who wish to experiment with numerous different published recipes. Fixed charge bars are rated for either lead or steel shot, but not for both. Universal charge bars, on the other hand, are capable of reloading both lead
Like their pistol and rifle counterparts, shotshell presses are available in both single
Shotshell presses are most commonly operated in non-batch modes. That is, a single hull will often be deprimed, reshaped, primed, loaded with powder, have a wad pressed in, be loaded with shot, be pre-crimped, and then be final crimped before being removed and a new hull being placed on the shotshell press at station 1. An alternative, somewhat faster method, often used on a single stage press is to work on 5 hulls in parallel sequentially, with but a single processed hull being located at each of the 5 stations available on a single stage shotshell press, while manually removing the finished shotshell from station 5 and then moving the 4 in-process hulls to the next station (1 to 2, 2 to 3, 3 to 4, 4 to 5) before adding a new hull at the deprimer (station 1) location. Both these modes of shotshell reloading are in distinct contrast to the common practice used with reloading pistol and rifle cartridges on a single
In general, though, shotshell reloading is far more complex than rifle and pistol cartridge reloading, and hence far fewer shotshell presses are therefore used relative to rifle and pistol cartridge reloading presses.
====.50 BMG and larger cartridge presses====
Reloading presses for reloading .50 BMG and larger cartridges are also typically caliber-specific, much like shotshell presses, as standard
=== Dies ===
[[File:Dies 7.5mm Swiss.jpg|thumb|right|Reloading dies and shell holders for 7.5mm Swiss]] [[Die (manufacturing)|Dies]] are generally sold in sets of two or three units, depending on the shape of the case. A three-die set is needed for straight cases, while a two
Standard dies are made from [[hardened steel]], and require that the case be lubricated, for the resizing operation, which requires a large amount of force. Rifle cartridges require lubrication of every case, due to the large amount of force required, while smaller, thinner handgun cartridges can get away with alternating lubricated and unlubricated cases. Carbide dies have a ring of [[tungsten carbide]], which is far harder and slicker than tool steel, and so carbide dies do not require lubrication.<ref name=nonte_2 />
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Modern reloading dies are generally standardized with 7/8-14 (or, for the case of [[.50 BMG]] dies, with 1-1/4×12) threads and are interchangeable with all common brands of presses, although older dies may use other threads and be press-specific.
Dies for
There are also specialty dies. Bump dies are designed to move the shoulder of a bottleneck case back just a bit to facilitate chambering. These are frequently used in conjunction with neck dies, as the bump die itself does not manipulate the neck of the case whatsoever. A bump die can be a very useful tool to anyone who owns a fine shooting rifle with a chamber that is cut to minimum headspace dimensions, as the die allows the case to be fitted to this unique chamber.<ref name=bumpdie>{{cite web|url=http://www.forsterproducts.com/Pages/precision_dies.htm |title=Precision Plus Bushing Bump Sizing Die |access-date=2007-09-14 |archive-url=https://web.archive.org/web/20070902000618/http://www.forsterproducts.com/Pages/precision_dies.htm |archive-date=2007-09-02 |url-status=dead }}</ref> Another die is the "hand die". A hand die has no threads and is operated—as the name suggests—by hand or by use of a hand-operated arbor press. Hand dies are available for most popular cartridges, and although available as full-length resizing dies, they are most commonly seen as neck sizing dies. These use an interchangeable insert to size the neck, and these inserts come in 1/1000-inch steps so that the user can custom fit the neck of the case to his own chamber or have greater control over neck tension on the bullet.<ref name=handdie>{{cite web |url=http://www.kinneman.com/browseproducts/KCP-Hand-Die-Reloading-Kit.HTML |title=KCP Hand Die Reloading Kit |access-date=2007-09-14}}</ref>
=== Shellholders ===
A
=== Scale ===
[[File:Powder Scale.jpg|thumb|right|Hornady Powder Scale]]
A precision [[weighing scale]] is a near necessity for reloading. While it is possible to load using nothing but a powder measure and a weight
A scale also allows bullets and cases to be sorted by weight, which can increase consistency further. Sorting bullets by weight has obvious benefits, as each set of matched bullets will perform more consistently. Sorting cases by weight is done to group cases by case wall thickness, and match cases with similar interior volumes. Military cases, for example, tend to be thicker, while cases that have been reloaded numerous times will have thinner walls due to brass flowing forward under firing, and excess case length being later trimmed from the case mouth.
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* Mechanical reloading scale (they are measured manually with no usage of power).
* Digital Scales (they need electricity or batteries to operate).
* Digital Scales with dispenser (they unite both reloading scales and dispense options into one version).<ref>{{Cite web|last=Hans|first=Wimberly|date=6 May 2021|title=Digital reloading scale|url=https://gearsadviser.com/best-digital-reloading-scale/
=== Priming tool ===
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=== Powder measure ===
[[File:Powder Dispenser.jpg|thumb|right|Hornady Powder Measure]]
Beginning reloading kits often include a weight-to-volume conversion chart for a selection of common powders
=== Bullet puller ===
[[File:Impact Bullet Puller.jpg|thumb|right|Impact Bullet Puller]]
Like any complex process, mistakes in handloading are easy to make, and a bullet puller device allows the handloader to disassemble mistakes. Most pullers use [[inertia]] to pull the bullet, and are often shaped like [[hammer]]s. When in use, the case is locked in place in a head-down fashion inside the far end of the "hammer", and then the device is swung and struck against a firm surface. The sharp impact will suddenly [[deceleration|decelerate]] the case, but the inertia exerted by the heavier [[mass]] of the bullet will keep it moving and thus pull it free from the case in a few blows, while the powder and bullet will get caught by a trapping container within the puller after the separation. [[Collet]]-type pullers are also available, which use a caliber-specific clamp to grip the bullet, while a loading press is used to pull the case downwards. It is essential that the collet be a good match for the bullet diameter
Bullet pullers are also used to disassemble loaded ammunition of questionable provenance or undesirable configuration
Primers are a more problematic issue. If a primer is not seated deeply enough, the cartridge (if loaded) can be pulled, and the primer re-seated with the seating tool. Primers that must be removed are frequently deactivated first—either firing the primed case in the appropriate firearm
Components pulled from loaded cartridges should be reused with care. Unknown or potentially contaminated powders, contaminated primers, and bullets that are damaged or incorrectly sized can all cause dangerous conditions upon firing.
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=== Case trimmer ===
[[File:Hornady Case Trimmer.jpg|thumb|right|Hornady Manual Case Trimmer]]
Cases, especially bottleneck cases, will stretch upon firing. How much a case will stretch depends upon load pressure, cartridge design, chamber size, functional cartridge headspace (usually the most important factor), and other variables. Periodically cases need to be trimmed to bring them back
Several kinds of case trimmers are available. Die-based trimmers have an open top
===Primer pocket tools===
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===Headspace gauges and modified case gauges===
Bottleneck rifle cartridges are particularly prone to encounter incipient head separations if they are full-length re-sized and re-trimmed to their maximum permitted case lengths each time they are reloaded. In some such cartridges, such as the [[.303 British]] when used in Enfield rifles, as few as 1 or 2 reloadings can be the limit
Similarly, by using modified case gauges, it is possible to measure precisely the distance from a bullet [[ogive]] to the start of rifling in a particular rifle for a given bottleneck cartridge. Maximum accuracy for a rifle is often found to occur for only one particular fixed distance from the start of rifling in a bore to a datum line on a bullet ogive. Measuring the overall cartridge length does not permit setting such fixed distances accurately, as different bullets from different manufacturers will often have a different ogive shape. It is only by measuring from a fixed diameter point on a bullet ogive to the start of a bore's rifling that
Such head space gauges and modified case gauges can, respectively, permit greatly increasing the number of times a rifle bottleneck case can be reloaded safely, as well as
== Materials required ==
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*[[Firearm brass|Cases]] or [[shotshell]] hulls. For shotshells, [[plastic]] or [[paper]] cases can be reloaded, though plastic is more durable. [[Steel]] and [[aluminum]] cases do not have the correct qualities for reloading, so a [[brass]] case is essential (although nickel-plated brass cases, while not as reformable as plain brass, can also be reloaded)
*[[Propellant]] of an appropriate type. Generally, [[List of handgun cartridges|handgun cartridges]] (due to shorter [[gun barrel|barrel]]s) and [[shotshell]]s (due to heavier projectile weights) use faster burning [[smokeless powder]]s, and [[rifle cartridge]]s use slower burning powder.
*[[Projectile]]s, such as [[bullet]]s for [[handgun]]s and [[rifle]]s, or [[shot (pellet)|shot]] and [[wadding|wad]]s for [[shotgun]]s.
*[[Centerfire]] [[primer (firearms)#Centerfire|primer]]s, most commonly a [[Centerfire ammunition#Boxer primer|Boxer-type]].
Case lubrication may also be needed depending on the dies used. [[Carbide]] pistol dies do not require case lubricant. For this reason, they are preferred by many, being inherently less messy in operation. In contrast, all dies for bottleneck cartridges, whether made of high
== Reloading process ==
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[[File:Case Tumbler.jpg|thumb|right|A vibratory ("dry") case Tumbler]]
The operations performed when handloading cartridges are:<ref name=nonte_4>Nonte, chapter 4, "Loading Metallic Cartridges"</ref>
*
* Case cleaning
* Case inspection
*
* Resizing — modifying the shape of the case neck/shoulder and/or removing any dents and deformities.
*[[Reamer|Ream]]ing or [[swage]] crimping the primer pocket (reloading military cases only), or [[Milling machine|mill]]ing the primer pocket depth using a primer pocket uniformer tool
*
*Deburring
*
* Expanding or chamfering the case mouth — to allow easier, smoother seating of the bullet before pressing (not required
* Cleaning the lubricant
*
*
*
*[[Crimp (joining)|Crimp]]ing — Pressing and tightening the case mouth to fix the bullet in place
*Final cartridge inspection
When previously fired cases are used, they must be inspected before loading. Cases that are dirty or tarnished are often polished in a tumbler to remove [[oxidation]] and allow easier inspection of the case. Cleaning in a tumbler will also clean the interior of cases, which is often considered important for handloading high-precision target rounds. Cracked necks, non-reloadable cases (steel, aluminum, or Berdan primed cases), and signs of [[case head separation|head separation]] are all reasons to reject a case. Cases are measured for length, and any that are over the recommended length
Removal of the [[Centerfire ammunition#Centerfire primers|primer]], called ''decapping'' or ''depriming'', is usually done with a die containing a steel pin that punches out the primer from inside the case. Berdan primed cases require a different technique, either a [[hydraulic]] ram or a hook that punctures the case and levers it out from the bottom. Military cases often have crimped-in primers, and decapping them leaves a slightly indented ring (most common) or, for some military cartridges, a set of stabbed ridges located on the edge of the primer pocket opening that inhibits or prevents seating a new primer into a decapped case. A reamer or a swage is used to remove both these styles of crimp, whether ring crimps or stab crimps.<ref name=nonte_4 /> The purpose of all such primer crimps is to make military ammunition more reliable under more extreme environmental conditions. Some military cartridges also have sealants placed around primers, in addition to crimps, to provide additional protection against moisture intrusion that could deactivate the primer for any ammunition exposed to water under battlefield conditions. Decapping dies, though, easily overcome the additional resistance of sealed primers, with no significant difficulty beyond that encountered when removing non-sealed primers.
When a cartridge is fired, the internal pressure expands the case to fit the chamber in a process called [[Obturate|obturation]]. To allow ease of chambering the cartridge when it is reloaded, the case is swaged back to size. Competition shooters, using [[bolt-action]] rifles that are capable of camming a tight case into place, often resize only the neck of the cartridge, called ''neck sizing'', as opposed to the normal full-length resizing process. Neck sizing is only useful for cartridges to be re-fired in the same firearm, as the brass may be slightly oversized in some dimensions for other chambers, but the precise fit of the case to the chamber will allow greater consistency and therefore greater potential accuracy. Some believe that neck sizing will permit a larger number of reloads with a given case in contrast to full
Once the case is sized down, the inside of the neck of the case will actually be slightly smaller than the bullet's diameter. To allow the bullet to be seated, the end of the neck is slightly expanded to allow the bullet to start into the case. Boattailed bullets need very little expansion, while unjacketed [[lead]] bullets require more expansion to prevent shaving of lead when the bullet is seated.<ref name=nonte_4 />
[[File:Primers Large Rifle.jpg|thumb|right|Large Rifle primers]]
Priming the case is the most dangerous step of the loading process
The quantity of gunpowder is specified by weight, but almost always measured by volume, especially in larger
Competition shooters also often sort bullets by weight, often down to 0.10 grain (6.5 mg) increments. The bullet is placed in the case mouth by hand
===Shotgun shells===
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Unlike the presses used for reloading metallic cartridges, the presses used for reloading shotgun shells have become standardized to contain 5 stations, with the exact configuration of these 5 stations arranged either in a circle or in a straight row. Nonetheless, the operations performed using the industry-standard 5 station shotshell presses when handloading shotshells with birdshot, although slightly different, are very similar as to when reloading metallic cartridges:
*Selecting an appropriate charge bar and powder bushing, or charge bar with shot bushing and powder bushing, or a universal charge bar (if used) for measuring shot and powder, for the shotshell press.
*Verifying that all components are properly selected (hull, primer, powder, wad, and shot). (No substitutions are allowed in components, nor in charge weights of shot and powder. The only substitution allowed is in the brand of shot and the size of the shot (#8, #9, etc. Also, no substitutions are allowed in the shot material itself (whether it is lead shot,
*Loading shot and powder in the press, and verifying that the as-dropped weights are per an established, published, loading recipe using a calibrated scale. (Typically, 5 to 10 trials of shot and powder drops, each, are recommended by shotshell press or universal charge bar user manuals.)
*Adjusting bushings or universal charge bar settings to account for small differences in densities due to lot-to-lot variations in both powder and shot.
*Inspecting each hull. (Examining for cracks or other hull defects, and discarding any visibly imperfect hulls. Also, turning each hull upside down to remove any foreign object debris before depriming.)
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*Cutting open 4 or 5 shells randomly selected from a large lot of handloaded shells, respectively, and verifying that the as-thrown weights of powder and shot are both within desired tolerances of the published recipe that was followed. (Optional, but recommended.)
The exact details for accomplishing these steps on particular shotshell presses vary depending on the brand of the press, although the presence of 5 stations is standard among all modern presses.
The use of safety glasses or goggles while reloading shotshells can provide valuable protection in the rare event that an accidental detonation takes place during priming operations.
The quantities of both gunpowder and shot are specified by weight when loading shotshells, but almost always measured solely by volume. A powder scale is therefore needed to determine the correct mass thrown by the powder measure, and by the shot measure, as powder loads are specified with a precision of 0.10 [[grain (mass)|grain]] (6.5 mg), but are usually thrown with a tolerance of 0.2 to 0.3 grains in most
Shotshell reloading for specialty purposes, such as for buckshot or slugs, or other specialty rounds, is often practiced
Modern shotshells are all uniformly sized for Type 209 primers. However, reloaders should be aware that older shotshells were sometimes primed with a Type 57 or Type 69 primer (now obsolete), meaning that shotgun shell reloading tends to be done only with modern (or recently produced) components. Being essentially "published recipe" dependent, antique shotshell reloading is not widely practiced, being more of a specialty, or niche, activity. Of course, when reloading for very old shotguns, such as those with Damascus barrels, special shotshell recipes that limit pressures to less than 4500 psi are still available, and these "recipes" are reloaded by some shotgunning enthusiasts. Typical shotshell pressures for handloads intended for modern shotguns range from approximately 4700 psi to 10,000 psi.
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Brass shotshells are also reloaded, occasionally, but typically these are reloaded using standard rifle/pistol reloading presses with specialty dies, rather than with modern shotshell presses. Rather than plastic wads, traditional felt and paperboard wads are also generally used (both over powder and over shot) when reloading brass shotgun shells. Reloading brass shotshells is not widely practiced.
Shotguns, in general, operate at much lower pressures than pistols and rifles, typically operating at pressures of 10,000 psi, or less, for 12 gauge shells, whereas rifles and pistols routinely are operated at pressures in excess of 35,000 psi, and sometimes upwards of 50,000 psi. The [[Sporting Arms and Ammunition Manufacturers' Institute|SAAMI]] maximum permitted pressure limit is only 11,500 psi for 12 gauge 2-3/4 inch shells, so the typical operating pressures for many shotgun shells are only slightly below the maximum permitted pressures allowed for safe ammunition.<ref name ="SAAMI_209">{{cite web |author=SAAMI |title=American National Standards Voluntary Industry Performance Standards for Pressure and Velocity of Shotshell Ammunition for the use of Commercial Manufacturers |url=http://www.saami.org/specifications_and_information/publications/download/209.pdf |access-date=1 March 2013 |archive-url=https://web.archive.org/web/20121115015926/http://www.saami.org/specifications_and_information/publications/download/209.pdf |archive-date=15 November 2012 |url-status=dead }}</ref> Because of this small difference in typical operating vs. maximum industry allowed pressures
== Legal aspects ==
Since many countries heavily restrict the civilian possession of ammunition and ammunition components, including [[Percussion cap|primers]] and [[smokeless powder]], handloading may be explicitly or implicitly illegal in certain countries. Even without specific restrictions on powder and primers, they may be covered under other laws governing [[explosive]] materials.<ref>{{cite web |url=http://www.opsi.gov.uk/SI/si2005/20051082.htm#10 |title=The Manufacture and Storage of Explosives Regulations 2005 |publisher=The Queen's Printer of Acts of Parliament}}</ref> Handloading may require study and passing an exam to acquire a handloading permit prior to being allowed to handload ammunition in some jurisdictions. This is done to avoid catastrophic accidents caused by lack of knowledge/skill as much as possible, and also allows the government to maintain information on who reloads their own cartridges. The standards organization [[C.I.P.]] rules that the products of handloaders that do not comply with the [[C.I.P.#Ammunition approval|C.I.P. ammunition approval rules]] for commercial ammunition manufacturers cannot be legally sold in [[C.I.P.#Member states|C.I.P. member states]].
Many firearms manufacturers explicitly advise against the use of handloaded ammunition. Generally, this means that the maker's warranty is void, and the manufacturer is not liable for any damage to the gun or personal injury if handloaded ammunition is used
===United States ===
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===Germany ===
As an example
As German law gives maximum pressures for every commercial caliber, the handloader is allowed to non-commercially give away his ammunition. He is liable for incorrect loading. His references are data
The relevant rules for non
In order to investigate gun destruction – material fault or incorrectly loaded ammunition – , and for handloaders to get data for new loads, gun and/or handloaded cartridges can be sent to the [[Deutsche Versuchs- und Prüfanstalt für Jagd- und Sportwaffen|DEVA]] institute (German institute for testing and examining of hunting and sporting guns);<ref>{{cite web| url = http://www.deva-institut.de| title = DEVA - Deutsche Versuchs- und Prüfanstalt für Jagd- und Sportwaffen}}</ref> the DEVA returns a pressure diagram and a report whether this load is within legal range for this ammunition.
=== South Africa ===
== Atypical handloading ==
Berdan primers, with their off-center flash holes and lack of self-contained anvil, are more difficult to work with than the easily removed Boxer primers. The primers may be punctured and pried out from the rear, or extracted with [[hydraulic]] pressure. Primers must be selected carefully, as there are more sizes of Berdan primers than the standard large and small pistol, large and small rifle of Boxer primers. The case must also be inspected carefully to make sure the anvil has not been damaged
[[Rimfire ammunition|Rimfire]] cartridges (e.g. [[22 Long Rifle]]) are not generally hand-loaded in modern times, although there are some shooters that unload commercial rimfire cartridges, and use the primed case to make their own loads
Some shooters desiring to reload for obsolete rimfire cartridges alter the firearm in question to function as a centerfire, which allows them to reload. Often it is possible to reform cases from similarly sized ammunition which is in production, and this is the most economical way of obtaining brass for obscure or out
An unusual solution to the problem of obtaining ammunition for the very old [[pinfire]] cartridges is even available. This solution uses specialized cartridges that use a removable pin and anvil which hold a percussion cap of the type use in caplock firearms. To reload a fired case, the pin is removed, allowing the anvil to slide out; a percussion cap is placed in the anvil, it is re-inserted, and the pin serves to lock the anvil in place, as well as to ignite the percussion cap.
Shotshell reloading is sometimes done for
== Accuracy considerations ==
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The internal volume of the cartridge case, or case capacity, significantly affects the pressure developed during ignition, which significantly affects the velocity of the bullet. Cases from different manufacturers can vary in wall thickness, and as cases are repeatedly fired and reloaded the brass flows up to the neck and is trimmed off, increasing capacity as well as weakening the case. The first step to ensuring consistent case capacity is sorting the cases by headstamp, so each lot of cases is from the same manufacturer and/or year. A further step would be to then weigh these cases, and sort by case weight.<ref name=frfrog />
The neck of the case is another variable
[[File:Common Empty Rifle Casings.jpg|thumbnail|right|Common Rifle Casings]]
===Bullets===
Bullets must be well balanced and consistent in weight, shape, and seating depth to ensure that they correctly engage the rifling, exit the barrel at a consistent velocity, and fly straight. Buying bullets from a high
The transition from the case to the barrel is also very important. If the bullets have to travel a varying distance from the case to the point where they engage the rifling, then this can result in variations in pressure and velocity. The bearing surface of the bullet should ideally be seated as close as possible to the rifling. Since it is the bearing surface that matters here, it is important that the bullets have a consistent bearing surface.<ref name=frfrog />
===Load tuning===
Tuning load to a gun can also yield great increases in accuracy, especially for standard, non-[[accurize]]d rifles. Different rifles, even of the same make and model, will often react to the same ammunition in different ways. The handloader is afforded a wider selection of bullet weights than can readily be found in commercially loaded ammunition, and there are many different powders that can be used for any given cartridge. Trying a range of bullets and a variety of powders will determine what combination of bullet and powder gives the most consistent velocities and accuracies. Careful adjustment of the amount of powder can give the velocity that best fits the natural harmonics of the barrel (see [[accurize]] and [[internal ballistics]]). For ultimate accuracy and performance, the handloader also has the option of using a [[wildcat cartridge]]; wildcats are the result of shaping the cartridge and chamber themselves to a specific end, and the results push the envelope of velocity, energy, and accuracy. Most, but not all, reloads perform best when the powder selected fills 95% or more of the case (by volume).<ref name=frfrog />
== Cost considerations ==
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Since the case is the single most expensive part of a loaded round, the more times a case can be re-used, the better. Cases that are loaded to a moderate pressure will generally last longer, as they will not be [[work hardening|work hardened]] or flow under pressure as much as cases loaded to higher pressures. Use of moderate pressure loads extends the life of the case significantly, not to mention saving quite a bit of wear and tear on the barrel.<ref>{{cite book|last=Warner|first=Ken|title=Gun Digest 1991|year=1990|publisher=DBI Books Inc.|isbn=978-0-87349-105-1|pages=151–152}}</ref> Work hardening can cause cracks to occur in the neck as the hardened brass loses its malleability, and is unable to survive swaging back into shape during the resizing operation. Rifle brass tends to flow towards the neck (this is why rifle brass must be trimmed periodically) and this takes brass away from the rear of the case. Eventually, this will show as a bright ring near the base of the cartridge, just in front of the thick web of brass at the base. If brass is used after this ring appears, it risks a crack, or worse, a complete head separation, which will leave the forward portion of the brass lodged in the chamber of the gun. This generally requires a special stuck case removal tool to extract, so it is very undesirable to have a head separation.<ref name=nonte_15 />
With bottlenecked cartridge cases, choosing the right sizing die can also be important. Full
Work hardening happens to all cases, even low-pressure handgun cases. The sudden increase in pressure upon firing hits the brass like a hammer, changing its crystalline structure and making it more brittle. The neck of the case, if it becomes too brittle, will be incapable of standing the strain of resizing, expanding, crimping, and firing, and will split during loading or firing. Since the case neck remains in tension while holding the bullet in place, aging ammunition may develop split necks in storage. While a neck split during firing is not a significant danger, a split neck will render the case incapable of holding the bullet in place, so the case must be discarded or recycled as a wildcat cartridge of shorter overall length, allowing the split section to be removed. The simplest way to decrease the effects of work hardening is to decrease the pressure in the case. Loading to the minimum power level listed in the reloading manual, instead of the maximum, can significantly increase case life. Slower powders generally also have lower pressure peaks
{{cite book |title=Complete Outdoors Encyclopedia: Revised & Expanded |author=Vin T. Sparano |year=1998 |publisher=Macmillan |isbn=0-312-19190-1 |page=[https://archive.org/details/completeoutdoors00spar/page/175 175] |url-access=registration |url=https://archive.org/details/completeoutdoors00spar/page/175 }}</ref>
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Powder is another significant cost of reloading, and one over which the handloader has significant control. In addition to the obvious step of using a minimum charge, rather than a full power one, significant cost savings may be obtained through careful powder choice. Given the same bullet and cartridge, a faster burning powder will generally use a smaller charge of powder than required with a slower powder. For example, a [[44 Magnum]] firing a 240-grain lead semi-wadcutter could be loaded with either Accurate Arms #2, a very fast pistol powder, or #9, a very slow pistol powder. When using the minimum loads, 9.0 grains (0.58 g) of AA #2 yield a velocity of 1126 ft/s (343 m/s), and 19.5 grains (1.26 g) of #9 yield 1364 ft/s (416 m/s). For the same amount of powder, AA #2 can produce approximately twice as many rounds, yet both powders cost the same per weight.
The tradeoff comes in terms of power and accuracy; AA #2 is designed for small cases
One solution that is applicable to [[revolver]]s, in particular, is the possibility of using a reduced-volume case. Cartridges such as [[357 Magnum]] and [[44 Magnum]] are just longer versions of their parent rounds of [[.38 Special]] and [[.44 Special]], and the shorter rounds will fire in the longer chambers with no problems. The reduced case capacity allows greater accuracy with even lighter loads. A 44 Special loaded with a minimum load of AA #2 uses only 4.2 grains (0.27 g) of powder, and produces a modest 771 ft/s (235 m/s).
When reloading .38 Special and .44 Special, extreme care must be exercised to not exceed maximum powder specifications - i.e. a 357 Magnum load must never be used in a .38 special case, as even though the powder charge may fit, the difference in case volumes will likely create an overpressure scenario resulting in unsafe conditions. == Bullets ==
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While the case is usually the most expensive component of a cartridge, the bullet is usually the most expensive part of the ''reloaded'' round, especially with handgun ammunition. It is also the best place to save money with handgun ammunition. This is because the bullets are used one time, and the case lasts for many reloadings.
Other advantages of casting or swaging bullets from lead wire (which is pricier but avoids many quality-control issues of casting) is the ability to precisely control many attributes of the resulting bullet. Custom bullet molds are available from a number of sources, allowing the handloader to pick the exact weight, shape, and diameter of the bullet to fit the cartridge, firearm, and intended use. A good example of where this is useful is for shooters of older military surplus firearms, which often exhibit widely varying bore and groove diameters; by making bullets specifically intended for the firearm in question, the accuracy of the resulting cartridges can be significantly increased.<ref name=nonte_8 />
=== Casting ===
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Similarly, cast lead buckshot is often cast by handloaders, for reloading into shotgun shells for hunting larger game animals. Such buckshot is then placed by hand into shotgun shells when handloaded, due to the necessity of having to stack the buckshot balls into specific configurations depending on the gauge of shotgun shell being reloaded, the choice of wad, the volume of powder, and the size of the buckshot (e.g., 00, 000, 0000 buckshot). Such cast lead buckshot is never simply dropped from a shotshell press charge bar into a shotgun shell when reloading.
=== Swaging ===
Most shooters prefer jacketed bullets, especially in rifles and pistols. The hard jacket material, generally copper or [[brass]], resists deformation and handles far higher pressures and temperatures than lead. Several companies offer [[swage|swaging]] presses (both manual and hydraulic) that will manufacture on a small scale jacketed bullets that can rival or surpass the quality of commercial jacketed bullets. Two swaging equipment manufacturers offer equipment and dies designed to turn [[22 Long Rifle]] cases into brass jackets for 22 caliber (5.56 mm) bullets.<ref name=nonte_8 />
Example variants of swage dies include:{{cn|date=January 2022}}
* ''R dies
* ''S dies'', steel dies for a manual press. They have a maximum caliber of {{convert|.458|in|mm}} and a maximum jacket length of {{convert|1.3|in|mm}}.
▲* R dies are used for bullet swaging in the reloading press. No expensive special press is needed; however, the reloading press cannot swage all calibers and variants of bullets.
*
Every bullet diameter, and most of the bullet types, need special dies, making swaging a rather investment-intensive enterprise.
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A more economical alternative was made available to the handloader in the 1980s, the copper-plated bullet.<ref>[http://www.rainierballistics.com/cohistory.htm Ranier Ballistics] {{webarchive|url=https://web.archive.org/web/20070928013832/http://www.rainierballistics.com/cohistory.htm |date=2007-09-28 }} has been making plated bullets since 1983.</ref> Copper-plated bullets are lead bullets that are [[electroplate]]d with a copper jacket. While thinner than a swaged bullet jacket, the plated jacket is far thicker than normal electroplate, and provides significant structural integrity to the bullet. Since the jacket provides the strength, soft lead can be used, which allows bullets to be swaged or cast into shape before plating. While not strong enough for most rifle cartridges, plated bullets work well in many handgun rounds, with a recommended maximum velocity of 1250 ft/s (375 m/s).<ref>[http://www.rainierballistics.com/faq.htm Ranier Ballistics] {{webarchive|url=https://web.archive.org/web/20070928013826/http://www.rainierballistics.com/faq.htm |date=2007-09-28 }} plated bullet FAQ, listing maximum recommended velocity</ref> Plated bullets fall between cast and traditional jacketed bullets in price.
While originally sold only to handloaders as an inexpensive substitute for jacketed bullets, the plated bullet has come far. The ammunition manufacturer [[CCI Ammunition|Speer]] now offers the Gold Dot line, commercially loaded premium handgun ammunition using copper-plated [[hollow point bullet]]s.<ref>[http://www.speer-bullets.com/html/products/ProdDesc.asp?prod=bullet_hand_GoldDot Speer Gold Dot description] {{Webarchive|url=https://web.archive.org/web/20090203042104/http://www.speer-bullets.com/html/products/ProdDesc.asp?prod=bullet_hand_GoldDot |date=2009-02-03 }} and patent number</ref><ref>[http://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO2&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=19&f=G&l=50&co1=AND&d=PTXT&s1=5,079,814&OS=5,079,814&RS=5,079,814 Patent 5,079,814] {{Webarchive|url=https://web.archive.org/web/20160124030337/http://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO2&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-bool.html&r=19&f=G&l=50&co1=AND&d=PTXT&s1=5,079,814&OS=5,079,814&RS=5,079,814 |date=2016-01-24 }}, for an electroplated hollow point bullet (the Speer Gold Dot)</ref> The strong bond between jacket and core created by the electroplating process makes expanding bullets hold together very well, and the Gold Dot line is now in use by many police departments.<ref>[http://www.firearmstactical.com/ammo_data/9mm.htm Comparison] {{Webarchive|url=https://archive.today/20130123054658/http://www.firearmstactical.com/ammo_data/9mm.htm |date=2013-01-23 }} of various 9×19mm expanding bullet loads, including the Speer Gold Dot plated bullet</ref>
== See also ==
* [[Pacific Tool Company]]
* [[Table of handgun and rifle cartridges]]
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== References ==
{{Reflist}}
== Citations ==
{{refbegin}}
* {{Cite book |last=Nonte Jr. |first=George C. |year=1978 |title=Basic Handloading |publisher=Outdoor Life |location=New York |lccn=77026482}}
{{refend}}
== Further reading ==
* ''[[Cartridges of the World]] 8th Edition'', Book by [[Frank Barnes (gunsmith)|Frank Barnes]], DBI Books, 1997, {{ISBN|0-87349-178-5}}
* ''Handbook for Shooters & Reloaders vol I, Book by [[P.O. Ackley]]''; Plaza Publishing, 1962, {{ISBN|978-99929-4-881-1}}
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* ''The Handloader's Manual of Cartridge Conversions'', Book by John J. Donnelly, Stoeger Publishing, 1987, {{ISBN|978-0-88317-269-8}}
* ''Designing and Forming Custom Cartridges'', Book by Ken Howell, Precision Shooting, 1995, {{ISBN|0-9643623-0-9}}
▲=== Reloading ===
* {{Cite book |last=Accurate |year=2000 |title=Accurate Smokeless Powders Loading Guide |edition=Number Two (Revised) |location=Prescott, AZ |publisher=Wolfe Publishing |id=Barcode 94794 00200}}
* ''Barnes Reloading Manual Number 3''; Edited by Dave Scovill, LP, 2001
* ''Black Powder Handbook & Loading Manual, 2nd Edition''; Book by Sam Fadala, Lyman Publications, 2001 UPC #011516971005
* {{Cite book |last=Hornady |year=2003 |title=Hornady Handbook of Cartridge Reloading |series=vol I |edition=6th |location=Grand Island, NE, USA |publisher=Hornady Mfg Co}}
* ''Lapua Shooting and Reloading Manual 2nd Edition''; Book by Nammo Lapua, LP, 2000, {{ISBN|951-97156-2-2}}
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* ''Speer Reloading Manual Number 13''; Book by Speer, Blount, Inc., 1998
* {{Cite book |author=Van Rensburg, H. |year=2013 |title=The Accurate Chain |url=http://www.africansunmedia.co.za/Sun-e-Shop/tabid/78/ProductId/355/Default.aspx |url-status=dead |edition=1st |location=Stellenbosch, South Africa |publisher=Rapid Access Publishers |isbn=9781919985480 |access-date=2015-01-12 |archive-url=https://web.archive.org/web/20150112152423/http://www.africansunmedia.co.za/Sun-e-Shop/tabid/78/ProductId/355/Default.aspx |archive-date=2015-01-12}}
== External links ==
* [https://web.archive.org/web/20080325202300/http://www.midwayusa.com/static.exe/getstaticpage?page=charts.htm MidwayUSA's Application charts and reloading information]
{{Handloading}}
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