Guys — honestly, if you do anything today on this site, watch this video. You won’t be disappointed. Guaranteed. This is a very informative (and surprisingly entertaining) video. Every serious hand-loader should watch this video to see how cartridge cases are made. Your Editor has watched the video 5 times now and I still find it fascinating. The camera work and editing are excellent — there are many close-ups revealing key processes such as annealing and head-stamping.
VERY Informative Video Show Cartridge Brass and Ammunition Production:
Norma has released a fascinating video showing how bullet, brass, and ammunition are produced at the Norma Precision AB factory which first opened in 1902. You can see how cartridges are made starting with brass disks, then formed into shape through a series of processes, including “hitting [the cup] with a 30-ton hammer”. After annealing (shown at 0:08″), samples from every batch of brass are analyzed (at multiple points along the case length) to check metal grain structure and hardness. Before packing, each case is visually inspected by a human being (3:27″ time-mark).
The video also shows how bullets are made from jackets and lead cores. Finally, you can watch the loading machines that fill cases with powder, seat the bullets, and then transport the loaded rounds to the packing system. In his enthusiasm, the reporter/narrator does sometimes confuse the term “bullets” and “rounds” (5:00″), but you can figure out what he means. We definitely recommend watching this video. It’s fascinating to see 110-year-old sorting devices on the assembly line right next to state-of-the art, digitally-controlled production machinery.
Video tip by EdLongrange. We welcome reader submissions.
Share the post "How Cartridge Brass (and Bullets) Are Made — Great Norma Video"
If you read our lengthy article on Ultrasonic Cleaning by Jason Baney, you’ve seen the remarkable results that can be achieved with this method, as shown by the photo above. Ultrasonic cleaning has many advantages over traditional tumbling methods of case cleaning. There is no dust or media residue to remove from the brass, and when done right, the cases come out clean and shiny, inside and out, even the primer pockets.
In its Benchtalk Archives, Brownell’s has an excellent article discussing Ultrasonic Case Cleaning. Brownell’s staff compares results, with measured dwell times from 5 to 75 minutes, using both Mpro-7 and HCS 200 cleaning solutions. Tests are performed with once-fired and 5X-fired Tactical 20 (Tac20) cases, as well as once-fired .260 Rem Cases. The article also compares the results from ultrasonic cleaning vs. tumbling in walnut media. Below are Brownell’s results for Tac20 cases with the HCS 200 (non-acidic solution). Go to Brownell’s article for MPro7 results and Rem 260 results.
HCS 200 Cleaning Solution Test
Procedure — Solution was de-gassed for 15 minutes, then 63 Tac20 cases were placed in a single layer, in stainless steel mesh basket. The temperature of the starting solution was 102° F. When the cases were removed the temperature was 110° F.
Once-Fired Tactical Twenty Cases (HCS 200) — Observations 5 minutes: The exterior of the cases are not significantly brighter/cleaner. The primer pockets and case interiors are still dirty. 10 minutes: Exterior of the cases are brighter. 70% of the cases show some degree of cleaning of the primer pockets. Little difference seen inside the case, but case mouths are cleaner. 15 minutes: Case brightness is about the same. Still only 70% of the primer pockets are clean, but a larger portion of each is cleaner. A Q-tip swabbed inside the cases shows that carbon/powder residues are loosening up. 20 minutes: Case exteriors are brightening up. 80-85% of the primer pockets are about 90% clean. The insides of the cases and case mouths are cleaner. 25 minutes: Cases are brighter/cleaner than even new brass. 80-85% of the cases have almost completely clean primer pockets. The inside of the cases are 80-90% clean. 30 minutes: The insides of the cases and case mouths appear to be completely clean. 87% of the primer pockets are virtually 100% clean. 13% of the cases had stubborn primer pocket residue that could not be completely removed. 60 minutes: Eight cases (13%) were placed in the tank for another 30 minutes to try to remove the remaining residue in their primer pockets. Six out of the eight cases were completely clean.
Five-Times Fired Tac20 Cases — Observations 30 minutes: Based on the above observations, I didn’t begin to observe these 5-time fired cases until after 30 minutes: The exterior cases are bright/clean. Brighter than new cases. The primer pockets on 75% of the cases are 75% clean. The remaining cases had primer pockets that were only 25% clean. The inside of the cases appear to be clean. 65 minutes: 25% of the primer pockets were 95% clean, 25% of the primer pockets were 90% clean, 25% of the primer pockets were 85% clean; and 25% were 80% clean. 75 minutes: 75% of the primer pockets were 90% clean.
How Does Ultrasonic Cleaning Work? The Brownell’s article explains: “Ultrasonic cleaning uses high-frequency sound waves (generally between 20-80 kHz) to remove a variety of contaminants from objects immersed in a liquid. The result of these high-frequency sound waves is a process called cavitation. These high frequency bursts of ultrasonic energy produce a three-dimensional wave of alternating positive and negative pressure areas as the sound wave passes through the solution. During negative pressure, microscopic cavitation bubbles form and will continue to grown until they reach resonant size. As the positive sound wave passes, the pressure rises rapidly and implodes these tiny bubbles. Before these minuscule bubbles implode they store a tremendous amount of energy. These bubbles can be as hot as 10,000 degrees and have as much as 50,000 lbs per square inch of pressure. This sounds alarming, but you have to remember that these bubbles are microscopic in nature and pose no harm to anything, unless you are a carbon /powder residue deposit on a cartridge case!
When this cavitation bubble implodes near your brass case, it transforms the bubble into a jet about 1/10th of its size. This jet of energy can travel as fast as 400 km/hour. At 43 kHz, as is the frequency for our L & R HCS 200 ultrasonic cleaner, this is happening 43,000 times per second. This micro-burst of extreme energy is responsible for removing contaminants from the surface of your cartridge brass. Ultrasonic cleaning can reach into crevices and inaccessible areas and remove surface debris that can’t be cleaned by any other process.”
Before you load that nice new cartridge brass for the first time, run an expander mandrel down the case necks. This will iron out dents and provide more uniform neck tension. Chose a mandrel diameter that provides appropriate neck tension.
Lapua brass is so good that you’ll be tempted to just load and shoot, if you have a “no-turn” chamber. However, some minimal case prep will ensure more uniform neck tension. Keeping your neck tension very uniform allows more consistent bullet seating. That, in turn, usually yields better accuracy, and lower Extreme Spread and Standard Deviation (ES/SD). Lapua brass, particularly 6mmBR, 6.5×47, 6.5 Creedmoor, and .308 Win comes from the factory with tighter-than-optimal necks. Before you seat bullets, at a minimum, you should inside chamfer the case mouths, after running an expander mandrel down the necks. The expander mandrels from both Sinclair Int’l and K&M will both leave the necks with enough neck tension (more than .001″) so you can then seat bullets without another operation. We suggest putting a bit of lube on the mandrel before running it down the necks — but remove any lube that gets inside the necks before seating bullets.
Both Sinclair and K&M Tools make a die body specifically to hold expander mandrels. The Sinclair version, is shown above. This $32.99 unit fits caliber-specific expander mandrels ($9.99) which measure approximately .001″ less than bullet diameter for each caliber. This is an updated “Gen II” design that completely captures the mandrel within the die so the mandrel cannot pull out. It also has an O-ring in the die cap that allows the mandrel to self-center within the case neck. Sinclair now offers three sizes of die bodies for expander mandrels: .17 -.338 Caliber (#749-011-715WS); .357 – .50 caliber (#749-008-843WS), and a special .50 Cal die body for large-diameter 50 BMG presses (#749-009-163WS, $39.99). All Generation II dies are machined from stainless steel and the standard diameter 7/8-14 dies include the Sinclair Stainless Steel Split Lock Ring.
Once you run the Sinclair expander mandrel down the necks of Lapua brass, after you account for brass spring-back, you’ll have about .002″ neck tension*. This will make the process of seating bullets go much more smoothly, and you will also iron out any dents in the case mouths. Once the case mouths are all expanded, and uniformly round, then do your inside neck chamfering/deburring. The same expander mandrels can be used to “neck-up” smaller diameter brass, or prepare brass for neck-turning.
Forum member Mike Crawford adds: “These expanders can also reduce runout from offset seating. Prior to bullet seating, expand the sized necks to force thickness variance outward. With the Sinclair system, the necks will springback fine, and will not be pulled out of center. This leaves plenty of tension, and bullets seated more centered. I do this, even with turned necks, to get improved seating.”
Mandrels vs. Expander Balls on Decapping Rods
If you haven’t acquired an appropriate expander mandrel for your brass, but you DO have a full-length sizing die with an expander ball, this will also function to “iron out” the necks and reduce tension. However, using a die with an expander ball will work the necks more — since you first size them down, then the ball expands them up again. Typically (but not always), run-out is worse when using an expander ball vs. an expander mandrel.
* This .002″ tension is what we have observed with Lapua 6mmBR, 6.5×47, 6.5 Creedmoor, and .308 Win brass. This might vary with much smaller or larger cases, and of course a different brand of brass might yield different results. If you get too little tension with your current mandrel, you can get a smaller-diameter mandrel from 21st Century Shooting. 21st Century even offers low-friction Titanium Nitride-coated mandrels.
Share the post "Why You Should Use Expander Mandrels on New Brass"
Ace tactical shooter and gunsmith Jim See of Elite Accuracy LLC recently tested a Frankford Arsenal rotary brass tumbler. Like the older Thumbler’s Tumblers, this can tumble your cases in a liquid solution. The wet-tumbling process worked very well Jim reports. Posting on Facebook, Jim noted: “I was super impressed with the Frankford Arsenal rotary tumbler and cleaning packs they sent me. I ran 350 pieces of brass for one hour. They now look great.” Jim appreciated not having to deal with dry tumbling media, such as crushed walnut shells. Dry media produces dust and can leave residues or clog flash-holes.
Interestingly, Jim recommends you try wet-tumbling WITHOUT using stainless media. At least give it a try. Tumbling without media simplifies the process and you don’t have to worry about pins stuck in flash-holes or case-necks*. Jim reports: “Stainless steel pins come with the Frankford kit, but mine hit the trash right out of the box. There is no need to clean the inside of your cases 100% and that’s all the pins add to the equation. The brass bumping brass with hot water and Frankford’s liquid cleaner works great all by itself.” One wag stated: “That’s great to hear. Stainless steel pins are a PITA.”
Other Facebook posters concurred with Jim’s evaluation of the Frankford Arsenal Rotary Tumbler:
“I’ve had one for a couple years, and it works well. I usually run about 250-300 Dasher cases at once in it. But I use the pins because I’m OCD about clean brass.” — David W.
“I’ve had one for a year and a half and it definitely works with or without pins.” — Luke C.
“I got one about six months ago and have yet to use any SS media. I just use some dawn, distilled water, and Lemi Shine®. Turns nasty 5.56 range brass bright and shiny.” — Brian D.
“I don’t use the pins either and use a combination of Dawn soap and Lemi Shine.” — Jon N.G.
This video shows how to assemble and operate the Frankford rotary tumbler. But note, Jim See does NOT feel that it is necessary to use stainless media.
How to Dry Your Brass — Hair Dryer Vs. Machine
The downside of wet tumbling is that you end up with a pile of wet brass at the end of the cleaning cycle. There are many ways to dry brass, from drying in the sun to using a kitchen oven (be careful not to “overcook” your brass). One Facebook poster asked Jim: “What is your drying method for wet brass, and how long does it take?”
Jim See replied: “To start I just drain off the dirty water, and rinse the brass with clean hot water. Then I roll the brass on a towel for 30 seconds and put the brass in a one-gallon bucket. Next I insert a hair dryer in the bucket (with the brass) and let it run for about 5 minutes. With this procedure, the drying process for me is done in less than 10 minutes.”
Jack Lanhart has another method: “I use a food dehydrator. It takes 30 to 45 minutes.”
For those who don’t want to mess with towels and hair dryers, Frankford Arsenal offers a matching Platinum Series Case Dryer that simplifies the process of drying brass. Lyman also makes an excellent Cyclone Case Dryer. These drying machines each cost about $65.00 and both have multiple levels so you can separate different types of cartridge brass. Lyman states that “The forced heated air circulation of the Cyclone will dry your brass inside and out within an hour or two, with no unsightly water spots.” The Lyman dryer can also be used for ultrasonically-cleaned gun parts.
*The Frankford Rotary tumbler does include media separators if you choose to use the provided pins or other media. CLICK HERE for diagram showing how to use media separators.
Share the post "How to Efficiently Wet-Tumble Cartridge Brass"
When we first ran this story a while back, it generated great interest among readers. By popular request, we’re reprinting this story, in case you missed it the first time around. — Editor
Precision Benchrest and F-Class shooters favor premium brass from Lapua, Norma, Peterson, or RWS. (Lake City also makes quality brass in military calibers.) Premium brass delivers better accuracy, more consistent velocities, and longer life. Shooters understand the importance of good brass, but many of us have no idea how cartridge cases are actually made. Here’s how it’s done.
The process starts with a brass disk stamped from strips of metal. Then, through a series of stages, the brass is extruded or drawn into a cylindrical shape. In the extrusion process the brass is squeezed through a die under tremendous pressure. This is repeated two or three times typically. In the more traditional “draw” process, the case is progressively stretched longer, in 3 to 5 stages, using a series of high-pressure rams forcing the brass into a form die. While extrusion may be more common today, RWS, which makes some of the most uniform brass in the world, still uses the draw process: “It starts with cup drawing after the bands have been punched out. RWS cases are drawn in three ‘stages’ and after each draw they are annealed, pickled, rinsed and subjected to further quality improvement measures. This achieves specific hardening of the brass cases and increases their resistance to extraordinary stresses.” FYI, Lapua also uses a traditional draw process to manufacture most of its cartridge brass (although Lapua employs some proprietary steps that are different from RWS’s methods).
After the cases are extruded or drawn to max length, the cases are trimmed and the neck/shoulder are formed. Then the extractor groove (on rimless cases) is formed or machined, and the primer pocket is created in the base. One way to form the primer pocket is to use a hardened steel plug called a “bunter”. In the photos below you see the stages for forming a 20mm cannon case (courtesy OldAmmo.com), along with bunters used for Lake City rifle brass. This illustrates the draw process (as opposed to extrusion). The process of draw-forming rifle brass is that same as for this 20mm shell, just on a smaller scale.
River Valley Ordnance explains: “When a case is being made, it is drawn to its final draw length, with the diameter being slightly smaller than needed. At this point in its life, the head of the draw is slightly rounded, and there are no provisions for a primer. So the final drawn cases are trimmed to length, then run into the head bunter. A punch, ground to the intended contours for the inside of the case, pushes the draw into a cylindrical die and holds it in place while another punch rams into the case from the other end, mashing the bottom flat. That secondary ram holds the headstamp bunter punch.
The headstamp bunter punch has a protrusion on the end to make the primer pocket, and has raised lettering around the face to form the headstamp writing. This is, of course, all a mirror image of the finished case head. Small cases, such as 5.56×45, can be headed with a single strike. Larger cases, like 7.62×51 and 50 BMG, need to be struck once to form a dent for the primer pocket, then a second strike to finish the pocket, flatten the head, and imprint the writing. This second strike works the brass to harden it so it will support the pressure of firing.”
Thanks to Guy Hildebrand, of the Cartridge Collectors’ Exchange, OldAmmo.com, for providing this 20mm Draw Set photo. Bunter photo from River Valley Ordnance.
Share the post "How Cartridge Brass Is Made — Production Secrets Revealed"
Tumblers and walnut/corncob media are old school. These days many shooters prefer processing brass rapidly with an ultrasonic cleaning machine. When used with the proper solution, a good ultrasonic cleaning machine can quickly remove remove dust, carbon, oil, and powder residue from your cartridge brass. The ultrasonic process will clean the inside of the cases, and even the primer pockets. Tumbling works well too, but for really dirty brass, ultrasonic cleaning may be a wise choice.
Our friend Gavin Gear recently put an RCBS Ultrasonic cleaning machine through its paces using RCBS Ultrasonic Case Cleaning Solution (RCBS #87058). To provide a real challenge, Gavin used some very dull and greasy milsurp brass: “I bought a huge lot of military once-fired 7.52x51mm brass (fired in a machine gun) that I’ve been slowly prepping for my DPMS LR-308B AR-10 style rifle. Some of this brass was fully prepped (sized/de-primed, trimmed, case mouths chamfered, primer pockets reamed) but it was gunked up with lube and looking dingy.”
UltimateReloader.com Case Cleaning Video (7.5 minutes):
Gavin describes the cleaning exercise step-by-step on UltimateReloader.com. Read Gavin’s Cartridge Cleaning Article to learn how he mixed the solution, activated the heater, and cycled the machine for 30 minutes. As you can see in the video above, the results were impressive. If you have never cleaned brass with ultrasound before, you should definitely watch Gavin’s 7.5-minute video — it provides many useful tips and shows the cleaning operation in progress from start to finish.
Ultra Dry Necks After Ultrasonic Cleaning — Some Suggestions
The Ultrasonic cleaning process gets cartridge brass so “squeaky clean” that increased force may be required to seat your bullets, or they may “grab” as they go in the necks. To reduce bullet-seating effort, you may benefit from adding a little dry case lube inside the case-neck before loading (use a nylon brush). Another trick is adding a teaspoon of Ballistol lube to the cleaning solution. That provides a trace lubricant inside the necks, but does not interfere with powder ignition in any way.
The latest Gen2 RCBS ultrasonic cleaning machine has a large 6.3-quart capacity. That’s nearly 100% larger than the first generation machine in Gavin’s video. The Gen2 machine, $385.49 on Amazon, features a second ceramic heater and transducer to better clean brass cases and firearm parts. The LED is easily programmable, and the timer can be set for up to 30 minutes of cleaning. The original 3.2 quart-capacity RCBS ultrasonic machine, as shown in Gavin’s video, is still available for $180.72 at Midsouth Shooters.
Share the post "Get Brass Ultra-Clean with Ultrasonic Machines"
Many shooters prefer to deprime their brass before resizing. That way they can tumble cases or keep primer debris off their main press. To deprime cases before sizing or cleaning you can use a Depriming Die (aka “decapping die”). This pushes out the spent primer without changing the neck or body of a case. Such decapping dies work fine, but they do require the use of a press. Here is a handy alternative — a cool tool that allows you to deprime brass anywhere — no press needed.
Handheld Primer Removal Tool From Frankford Arsenal
This cleverly-designed Hand Deprimer Tool allows you to deprime cartridge cases without a press. This hand-tool from Frankford Arsenal will deprime brass and capture primers conveniently. You can deprime your cases while watching TV or relaxing in your favorite chair.
This device lets you remove spent primers anywhere — no press needed and all the mess (cups/anvils/residue) stays in the capture chamber. This tool comes works with nearly all common case types up to .338 Lapua Magnum. With good leverage, this tool does the job quicklyi and efficiently. Forum members have praised this handy tool, but recommend wearing a thick glove if doing more than 100 cases in a sesssion.
This handy depriming tool is very versatile. With a universal, cylinder-style cartridge-holder, the tool can deprime a wide variety of cartridge types from .20 caliber up to .338 caliber. Three different plastic collets are provided to handle for different diameter cases. Spent primers are captured in a removable spent primer catch tube. Simply twist off the clear catch tube to dump the spent primers. With die-cast metal construction, this tool should last through many thousands of depriming cycles. MSRP is $54.99. Right now it is $44.99 on Amazon with 82% 5-star ratings.
User Modifications — Grip Padding and High-Volume Capture
Many users recommended putting some kind of padding on the grip and front lever to reduce pressure on the fingers. This can be done with a wrap or a rubber covering. In addition, users have adapted the unit with an attached hose and large primer capture jug. If you depriming hundreds of cases at a time, this hose conversion may make sense.
Review from actual owner: “I have owned one of these for about eight years and deprimed over 10,000 cases with this tool. I have never had to replace a single part on it. You will have to adjust the return spring every so often, but that is a very easy task. If you are depriming a LOT of brass, the handle can tear up your hand a bit. Solution: Wear a Mechanics Glove. Easy Peasy! You will NOT regret this purchase.”
How to Adapt Tool for Small Flash Hole Brass
The Frankford Arsenal Deprimer Tool was designed for LARGE flash-hole brass. To deprime brass with small (1.5mm/0.59″) small flash-holes, as found on Lapua .220 Russian and 6mmBR cases, you will need to reduce the pin diameter. A smaller pin is “in development” according to the manufacturer. Frankford Arsenal currently recommends purchasing a replacement pin and “sanding it down” to the smaller diameter. NOTE: This is NOT difficult — simply spin the stock pin in some sandpaper.
Share the post "Frankford Deprimer Tool — Deprime Cases without a Press"
In April 2020, the National Rifle Association (NRA) launched NRAWomen.com, a website dedicated to the fastest-growing group of firearm owners — America’s women. This website serves the increasing number of female gun owners, huntresses, and competitive shooters. Female involvement in firearms is growing significantly. Consider these numbers: Statistica estimates that 19% of women in the USA owned firearms in 2020, while 23% of women surveyed in a 2011 Gallup Poll stated they owned a gun.
Here are four videos from the NRAWomen.com website, all worth watching. For each example, click the links to read the related articles on NRAWomen.com.
1. How to Sight-In Your Hunting Rifle
This video and related article offer good basic advice for sighting-in a hunting rifle. There are a series of six points covered. Here’s Tip #1: “Find a safe place to shoot your rifle with a backstop. If possible, use a bench and a rock-solid shooting rest. Sighting-in is all about consistency, so the less human error you have, the better. For safety, be sure to also bring ear and eye protection.” READ FULL ARTICLE on NRAWomen.com.
2. Buying Your First Handgun — Factors to Consider
Buying your first firearm can be overwhelming, with all the choices available. And personal preference/fit are especially important with handguns that may be carried on your person. This video follows two first-time buyers as they select their first handgun. The video explains factors to consider: Ergonomics, Accuracy, Caliber, Concealability, Recoil, Reliability, and Price. RELATED Articles on NRAWomen.com.
3. Cartridge Case Material Varieties — Brass, Nickle-Plated Brass, Aluminum, Steel Alloy
The case of a cartridge holds bullet, powder, and primer. Brass cases are most popular, but nickle-plated brass cases are also common and reloadable (though they generally don’t last as long as plain brass). Major manufacturers produce aluminum-cased pistol ammo, such as CCI Blazer. Aluminum pistol cases can shoot great, but are not (normally) reloadable. Finally, some large manufacturers, mostly foreign, produce steel-cased ammo. All different case types have certain advantages and disadvantages, though conventional brass is definitely the best choice for hand-loaders. This video explains pros and cons of each type of cartridge case construction. RELATED Articles on NRAWomen.com.
4. Modular Safes — Smart Option for Easier Moving
This article features a great video showing how to assemble a modular safe in under 30 minutes. This article also explains the benefits of modular gunsafes — primarily easier transport and installation. “Modular safes have been around for a few years now and are becoming more popular. Here’s why: The safe comes delivered to you in panels, so you can bring them into your home one at a time and put it together anywhere you like. This makes it easy to carry up and down stairs, onto elevators or anywhere! Security — Is it as secure as one that comes pre-assembled? The answer is, absolutely.” READ FULL ARTICLE on NRAWomen.com.
Share the post "Four Videos from NRAWomen.com — Not Just for the Ladies"
Have you ever expanded a .22 or 6mm cartridge all the way up to .30-caliber? If so, you know this can be a difficult procedure that stresses the case necks and neck-shoulder junction. A significant neck-size expansion done in one big jump can increase run-out, cause doughnuts, or worse yet, even split the brass. Therefore you want to proceed in increments, increasing the neck diameter in stages. One smart way to do that is to use a Progressive Press. This article explains how…
The most successful short-range benchrest-for-score cartridge is the 30 BR. That cartridge, as well as 30 BR variants such as the 30 BRX, all start with the 6mmBR Norma parent cartridge, typically with Lapua 6mmBR brass. To get a nice 30 BR case you want to expand in stages, increasing the inside neck diameter incrementally from .243 to .308.
Darrell Jones of DJ’s Brass Service creates thousands of 30 BR cases each year. He has found a clever way to speed up the process — Darrell uses a Progressive Press. He runs his 6BR brass through four (4) separate Hornady neck-sizing dies with expander mandrels. First there is a .257 die, followed by .264 (6.5mm), .284 (7mm), and then .308. Then a fifth and final K&M die provides one last, slight expansion so the newly-fashioned 30 BR cases perfectly fit the arbor of Darrell’s neck-turning tool.
So to repeat, the case starts as .243 (6mm), then moves in up stages .257, .264, .284, and .308, with a final “finishing” step prior to neck-turning. You can see the expansion in this video, which starts with 6mmBR brass that was first hydro-formed to 6 BRX:
Watch 6mm Cases Expanded to 30-Caliber (6BRX to 30 BRX)
For this demo video, Darrell expands just one case at a time. However, he can also put multiple cases in the progressive — one per station. This takes a little more effort, Darrell says, but the results are still excellent. Darrell tells us: “I do put multiple cases in the progressive to save time. The results are the same — I just wanted to show a single-step process and how it reduces run-out by not stressing the shoulder with one big expansion from 6mm straight to 30 caliber. Doing the operation in multiple stages avoids binds and helps keep the shoulders concentric.”
This same multi-stage procedure can be use to expand other cartridge types. For example you could take .221 Fireball brass in stages up to .308 to create 300 Blackout brass.
Darrell uses caliber-specific, Hornady neck-sizing-only dies with elliptical expanders. Darrell tells us: “The Hornady elliptical expander has a reduced bearing surface that puts less strain on the brass when expanding the necks to the next size.” The fitting at the bottom of the die is the Lock-N-Load die bushing that allows fast die changes.
These particular cases used in the video were first hydro-formed to 6BRX then expanded to 30 BRX before neck turning. DJ’s Brass offers hydro-forming for many popular wildcat cartridges such as 6 PPC, 6mm Dasher, and .284 Shehane.
Share the post "Expanding Cartridge Brass in Stages with Progressive Press"
Caldwell Brass Retriever
Tired of bending over or kneeling down to retrieve your fired cartridge brass? For older shooters (including this Editor) getting down on the ground to pick up brass is tough on the lower back and knees. Here’s a product that makes brass retrieval quick, easy, and pain-free. The Caldwell Brass Retriever works quite well with a little practice, once you apply the correct pressure. While it won’t always grab every fired case, it will capture nearly all, and that can really make the job go much faster.
One owner praises this as a “very good tool” that is “a lot easier on my back.” While it can work on grass, gravel, and hard-packed earth, the unit works best on smooth, hard surfaces. Currently priced under $40, it is a good value.
Caldwell states: “Spend less time bending over and picking up brass at the range and more time shooting. The Caldwell® Brass Retriever picks up brass, saving your back and time. Picking up spent brass is as easy as pushing a mop. The Brass Retriever can pick up rifle and pistol brass quickly and efficiently. The Brass Retriever works anywhere, even on grass and gravel. The retriever comes complete with a roll cage separator that allows you to dump the collected brass into a bucket quickly. It is collapsible as well, making it convenient to transport. The retriever’s handle expands from 28″ up to 57″ tall.”
Brass Retriever Owner Reviews
Here are Amazon reviews from actual purchasers. It’s clear the device is not perfect and can miss a case or two. However, as you can see from the videos, the Brass Retriever does grab the vast majority of brass on the ground, sized .223 Rem or larger diameter. This will save time and reduces stress on your back and joints:
“This thing … does a terrific job of collecting the brass from a standing posture quickly and efficiently. It helps to have the cases on a smooth surface like concrete or dirt without a lot of vegetation. But we used it on open desert yesterday and it collected nearly every case with a single pass. It’s now a permanent piece of gear in the stuff we take when target or ground squirrel shooting.” — Hans H.
“This WILL save your back. The only drawback is you can’t overload it with brass. After couple dozen pieces (or less) it will start dropping brass while you’re attempting to collect others. That’s the limitation (one of them). There is a short learning curve (15 min.) in which you’ll learn how much brass is too much And how you need to orientate the wires to pick up the brass. It doesn’t do as well on gravel or high grass as it does on a smooth, firm surface. Even with its limitations, it’s a keeper. Just empty every dozen or so pieces and it works very well. It comes with a wire form that attaches to a bucket for easy emptying. I normally just use my fingers to spread wires and give a shake to allow the contents to fall out. Again not perfect but when used within its design capabilities, it does pretty well. I would buy again.” — Jeff M.
“It’s not perfect. But neither is using a broom or picking it up by hand. Sure, a 9mm might drop out while you’re picking up a .45 ACP. But you roll back over the 9mm and pick it up again. I now pick up my brass in a fraction of the time it used to take me and I stand upright while doing it. I should add the disclaimer that I’ve only used it to pick up handgun brass and it’s picked up everything from .22 LR to .44 Magnum. I have not tried it with rifle brass.” — Johnny C.
Specialized Tool for .22 LR Brass
NOTE: The Caldwell Brass Retriever is designed primarily to recover reloadable rifle and pistol brass, with case diameters as fat as .223 Rem or larger. Some people state it can be used for smaller .22 LR cartridges too, but there is a much better product for that.
The UniqueTek Rimfire Brass Wizard is optimized for picking up .22 LR rimfire cases. It has a smaller basket with wires spaced closer together. It can also pick up pistol and rifle cartridge brass but will hold fewer cases than the original Brass Wizard or the Caldwell Brass Retriever.
Share the post "Caldwell Brass Retriever — Handy Item That Saves Your Back"
Tumblers and walnut/corncob media are old school. These days many shooters prefer processing brass rapidly with an ultrasonic cleaning machine. When used with the proper solution, a good ultrasonic cleaning machine can quickly remove remove dust, carbon, oil, and powder residue from your cartridge brass. The ultrasonic process will clean the inside of the cases, and even the primer pockets. Tumbling works well too, but for really dirty brass, ultrasonic cleaning may be a wise choice.
Our friend Gavin Gear recently put an RCBS Ultrasonic cleaning machine through its paces using RCBS Ultrasonic Case Cleaning Solution (RCBS #87058). To provide a real challenge, Gavin used some very dull and greasy milsurp brass: “I bought a huge lot of military once-fired 7.52x51mm brass (fired in a machine gun) that I’ve been slowly prepping for my DPMS LR-308B AR-10 style rifle. Some of this brass was fully prepped (sized/de-primed, trimmed, case mouths chamfered, primer pockets reamed) but it was gunked up with lube and looking dingy.”
UltimateReloader.com Case Cleaning Video (7.5 minutes):
Gavin describes the cleaning exercise step-by-step on UltimateReloader.com. Read Gavin’s Cartridge Cleaning Article to learn how he mixed the solution, activated the heater, and cycled the machine for 30 minutes. As you can see in the video above, the results were impressive. If you have never cleaned brass with ultrasound before, you should definitely watch Gavin’s 7.5-minute video — it provides many useful tips and shows the cleaning operation in progress from start to finish.
Ultra Dry Necks After Ultrasonic Cleaning — Some Suggestions
The Ultrasonic cleaning process gets cartridge brass so “squeaky clean” that increased force may be required to seat your bullets, or they may “grab” as they go in the necks. To reduce bullet-seating effort, you may benefit from adding a little dry case lube inside the case-neck before loading (use a nylon brush). Another trick is adding a teaspoon of Ballistol lube to the cleaning solution. That provides a trace lubricant inside the necks, but does not interfere with powder ignition in any way.
The latest Gen2 RCBS ultrasonic cleaning machine has a large 6.3-quart capacity. That’s nearly 100 percent larger than the first generation machine in Gavin’s video. The Gen2 machine, $322.02 on Amazon, features a second ceramic heater and transducer to better clean brass cases and firearm parts. The LED is easily programmable, and the timer can be set for up to 30 minutes of cleaning. The original 3.2 quart capacity RCBS ultrasonic machine, as shown in Gavin’s video, is still available for $166.56 at Midsouth Shooters.
Share the post "How to Clean Cartridge Brass with Ultrasonic Cleaning Machines"
We are re-publishing this article at the request of Forum members who found the information very valuable. If you haven’t read this Safety Tip before, take a moment to learn how you can inspect your fired brass to determine if there may be a potential for case separation. A case separation can be dangerous, potentially causing serious injury.
On the respected Riflemans’ Journal blog there was an excellent article about Cartridge Case-Head Separation. In this important article, Journal Editor GS Arizona examined the causes of this serious problem and explained the ways you can inspect your brass to minimize the risk of a case-head separation. As cases get fired multiple times and then resized during reloading, the cases can stretch. Typically, there is a point in the lower section of the case where the case-walls thin out. This is your “danger zone” and you need to watch for tell-tale signs of weakening.
The photo below shows a case sectioned so that you can see where the case wall becomes thinner near the web. You can see a little arrow into the soot inside the case pointing to the thinned area. This case hadn’t split yet, but it most likely would do so after one or two more firings.
Paper Clip Hack for Detecting Problems
The article provided a great, easy tip for detecting potential problems. You can use a bent paper clip to detect potential case wall problems. Slide the paper clip inside your case to check for thin spots. GS Arizona explains: “This simple little tool (bent paper clip) will let you check the inside of cases before you reload them. The thin spot will be immediately apparent as you run the clip up the inside of the case. If you’re seeing a shiny line on the outside and the clip is really hitting a thin spot inside, it’s time to retire the case. If you do this every time you reload, on at least 15% of your cases, you’ll develop a good feel for what the thin spot feels like and how it gets worse as the case is reloaded more times. And if you’re loading the night before a match and feel pressured for time — don’t skip this step!”
Share the post "Case-Head Separation — How to Detect Potential Problems"
Norma has released a fascinating video showing how bullet, brass, and ammunition are produced at the Norma Precision AB factory which first opened in 1902. You can see how cartridges are made starting with brass disks, then formed into shape through a series of processes, including “hitting [the cup] with a 30-ton hammer”. After annealing (shown at 0:08″), samples from every batch of brass are analyzed (at multiple points along the case length) to check metal grain structure and hardness. Before packing, each case is visually inspected by a human being (3:27″ time-mark).
If you read our lengthy article on 
The Brownell’s article explains: “Ultrasonic cleaning uses high-frequency sound waves (generally between 20-80 kHz) to remove a variety of contaminants from objects immersed in a liquid. The result of these high-frequency sound waves is a process called cavitation. These high frequency bursts of ultrasonic energy produce a three-dimensional wave of alternating positive and negative pressure areas as the sound wave passes through the solution. During negative pressure, microscopic cavitation bubbles form and will continue to grown until they reach resonant size. As the positive sound wave passes, the pressure rises rapidly and implodes these tiny bubbles. Before these minuscule bubbles implode they store a tremendous amount of energy. These bubbles can be as hot as 10,000 degrees and have as much as 50,000 lbs per square inch of pressure. This sounds alarming, but you have to remember that these bubbles are microscopic in nature and pose no harm to anything, unless you are a carbon /powder residue deposit on a cartridge case!
When this cavitation bubble implodes near your brass case, it transforms the bubble into a jet about 1/10th of its size. This jet of energy can travel as fast as 400 km/hour. At 43 kHz, as is the frequency for our L & R HCS 200 ultrasonic cleaner, this is happening 43,000 times per second. This micro-burst of extreme energy is responsible for removing contaminants from the surface of your cartridge brass. Ultrasonic cleaning can reach into crevices and inaccessible areas and remove surface debris that can’t be cleaned by any other process.”
Precision Benchrest and F-Class shooters favor premium brass from 
The headstamp bunter punch has a protrusion on the end to make the primer pocket, and has raised lettering around the face to form the headstamp writing. This is, of course, all a mirror image of the finished case head. Small cases, such as 5.56×45, can be headed with a single strike. Larger cases, like 7.62×51 and 50 BMG, need to be struck once to form a dent for the primer pocket, then a second strike to finish the pocket, flatten the head, and imprint the writing. This second strike works the brass to harden it so it will support the pressure of firing.”
Specialized Tool for .22 LR Brass
On the respected Riflemans’ Journal blog there was an excellent article about Cartridge Case-Head Separation. In this important article, Journal Editor GS Arizona examined the causes of this serious problem and explained the ways you can inspect your brass to minimize the risk of a case-head separation. As cases get fired multiple times and then resized during reloading, the cases can stretch. Typically, there is a point in the lower section of the case where the case-walls thin out. This is your “danger zone” and you need to watch for tell-tale signs of weakening.
