After the Berger Southwest Nationals, we had a long chat with John Whidden, five-time NRA Long-Range National Champion, and a past SWN Sling Division winner. When the subject turned to reloading techniques, John reminded us that he uses a Dillon progressive presss to load much of his match ammo — with a system for much more precise control over powder charge weight. Yes John loaded his national-championship winning .243 Win ammo on a progressive. That may not work for the benchrest game, but John proved this method works well for his discipline — long range sling shooting.
John full-length sizes his match brass every time using a Whidden click-adjustable sizing die. The powder charge is dispensed with single-kernel precision using an Auto-Trickler and lab-grade force restoration scale. The process is completed on a Dillon XL 650 to produce more ammo in less time.
Whidden’s .243 Win Ammo is Loaded on a Dillon
John Whidden of Whidden Gunworks used the .243 Winchester cartridge to win the 2017 NRA Long Range Championship, his FIFTH LR title. John loaded his .243 Win ammo using a Dillon: “My loading process is different than many people expect. I load my ammo on a Dillon 650 progressive press using our own Whidden Gunworks dies. However powder charges are individually weighed with a stand-alone automated scale/trickler system from AutoTrickler.com (see below). Employing a high-end force restoration scale, this micro-processor controlled system offers single-kernel precision. The weighed charges are then dropped into the cases with a funnel mounted to the Dillon head.”
John Whidden Explains His Ammo-Loading Process
The Lapua .243 Win brass is full-length sized every time, and I run one of our custom-sized expanders in my sizer die. The expander measures .243″ which yields the desired .001″ neck tension. In my experience, the best way to get consistent neck tension is to run an expander in the case neck at some point. When sizing the case neck by a minimal amount such as is the case here, I don’t find any negative points in using an expander in the sizer die.
Championship-Winning Load: Berger Bullets, Lapua Brass, and Vihtavuori N160
For a load, currently I’m shooting Lapua brass, PMC primers (Russian, similar to Wolf), VihtaVuori N160 single-base powder, and Berger 105 grain Hybrid bullets. I switched to the Hybrid bullets at the beginning of the 2015 season. Previously I shot the 105gr Berger hunting VLDs, and in testing I found that the Hybrids were just as accurate without having to seat the bullet into the lands. The velocity of this combination when shot through the excellent Bartlein 5R barrels (32” length) is around 3275 FPS.
For my match ammo, I seat the Berger 105 Hybrids well off the lands — my bullets are “jumping” from .035″-.060″. I only use one seating depth for ammunition for multiple guns (I know some benchrest shooters will stop reading right here!) and the bullets jump further in the worn barrels than in the fresh barrels. The bullets are pointed up in our Bullet Pointing Die System and are moly-coated. The moly (molybdenum disulfide) does extend the cleaning interval a little bit, probably 20% or so. The Lapua .243 Win brass is all neck-turned to .0125″ thickness.
In my experience, the keys to accurate long range ammo are top quality bullets and the most consistent neck tension you can produce. From these starting points, the use of quality components and accurate powder measurement will finish out the magic.
Great Ballistics with 6mm 105s at 3275 FPS
Running at an impressive 3275 FPS, Berger 6mm 105 grain Hybrids deliver ballistics that are hard to beat, according to John Whidden:
“My .243 Win shoots inside a 6.5-284 with 142-grainers. Nothing out there is really ahead of [the .243], in 1000-yard ballistics unless you get into the short magnums or .284s and those carry a very significant recoil penalty. In the past I did shoot the 6.5-284. I went to the .243 Win because it had similar ballistics but had much less recoil. It doesn’t beat me up as much and is not as fatiguing.
With the .243 Win, there’s no tensing-up, no anticipating. With the reduced recoil (compared to a 7mm or big .308), I can break and shoot very good quality shots. I find I just shoot better shots with the .243 than I ever did with the 6.5-284.”
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Here’s a smart product for folks who load and store large quantities of ammunition. With these white cardboard ammo boxes from Repackbox.com, you can store pistol, rifle, and shotshell ammo very inexpensively. A set of 30 boxes costs $13.95 ($0.47/box), while a 100-Box Bundle costs just $22.95. That works out to just $0.23 (twenty-three cents) per box — very cheap!
All boxes are Made in the USA of .024 thick, acid free, virgin card stock. The boxes are printed with Cartridge Type (Caliber), number of rounds enclosed, and an outlined box where a printed label can be placed. Included with each set are Blank Avery 5167 Labels which can be printed with load/bullet data or other info. The box kits even come with white gloves to keep your ammo grease-free. Order these ammo repack box kits from Repackbox.com.
There are many advantages to these cardboard boxes. They are inexpensive and they store ammo very efficiently, not using much space. You can arrange them in any orientation (unlike some plastic ammo carriers). We like these boxes for varmint safaris and other adventures when we’re transporting many hundreds of rounds of ammo. They are also a smart choice for bulk shotshell ammo, as they are much less expensive than plastic shotshell cases. For pistol shooting we still like see-through, plastic flip-top boxes at the range, but these white cardboard boxes are great for storing large quantities of pistol ammo produced on progressive presses. NOTE: These boxes do NOT have individual dividers between the cartridges. And no, the boxes are NOT waterproof — you’ll want to keep them in an ammo can on rainy days.
30-Box and 100-Box Kits are available for all these Pistol and Rifle Cartridge Types:
PISTOL Cartridges
.380 ACP
.38 SPL/.357 Magnum
9mm Luger
.40 S&W
10mm
.44 Magnum
.45 ACP
.45 Long Colt
RIFLE Cartridges
.223 Rem/5.56×45
.30 Carbine
30-30 Winchester
.303 Brit
7.62×39
.308 Win/7.62×51
7.62x54R
.30-06 Springfield
In addition, there are boxes for 12 gauge shotgun ammunition.
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What can happen when the bottom-most primer in a primer feed tube goes off? A big bang, that’s what. Some or all of the primers in the vertical feeding tube can go off in a chain detonation. That’s exactly what happened to Dustin Ellermann, Top Shot Season 3 Champion. Scary experience, but thankfully Dustin was not injured. He writes: “Super thankful that I was wearing my Wiley X eye protection this weekend when I was reloading some .223 rounds. My press detonated nearly 100 small rifle primers. Shown here is the magazine feed tube. Not fun but it could have been much worse. Stay safe!”
When working with progressive reloading presses, you should definitely wear eye protection. Dustin’s chain detonation experience proves that — without a doubt. Remember you only have one set of eyes!
RCBS APS Strips — Alternative to Primer Tubes When you stack a column of primers in a single metal tube, you’re asking for trouble. As Dustin Ellermann learned, when one primer fires, the entire column can follow suit in a chain detonation. Thankfully, you do have options when it comes to primer feeding on a progressive press. RCBS developed an innovative primer system for its Pro-2000 progressive press. Instead of being stored in a vertical tube, primers are placed in flat, plastic “APS” strips, with a ring of plastic separating each primer. Moving horizontally, primers are never stacked, so the chance of a chain detonation is reduced dramatically. The re-usable APS strips are color-coded for different primer types. You can buy CCI “pre-loaded” primer strips, or you can insert any brand of primers into strips using an RCBS strip-loader tool.
RCBS Pro-2000 with APS Strip Priming System
AccurateShooter.com Editor Uses Strip Primers
This Editor owns an RCBS Pro-2000 progressive press. The RCBS strip-priming system was one key reason I selected the RCBS Pro-2000 over similar-priced progressives from Dillon and Hornady. I believe the strip primer system is safer, more positive, and easier to use. Before I purchased my RCBS progressive, I “road-tested” the competition. I loaded hundreds of rounds on each of four different progressives: Dillon 550B, Dillon 650, Hornady Lock-N-Load, and RCBS 2000. I was concerned about the primer feed tubes on the Dillons, and I found the RCBS rotary powder measure was much more precise (and easier to adjust) than the sliding bar system on the Dillon machines. The RCBS priming system was definitely more fool-proof than the system on the Hornady press (a first-generation L-N-L that had issues with primer feeding). After “test-driving” blue, red, and green brand progressives extensively, I settled on the RCBS Pro-2000. A decade later, I still think I made the right choice. I like the APS strips for big jobs, and I can also use them in the RCBS hand-priming tool (shown below). With the strips, it’s easy to prime 20 or 40 cases at a time, and then switch to another type of primer for comparison testing.
The APS priming system also works with press-mounted priming tool, bench-mounted tool, and APS hand-tool. EdLongRange uses the press-mounted tool: “I also like the APS approach but use the press-mounted unit (saves your hands/wrists — and I haven’t had a need for a progressive press in over 20 years). Loading the primers in the strips is a bit of a PITA but very manageable. As with all tools there is a learning curve.” CLICK HERE for video showing strip-loading tool and press-mounted APS tool. The press-mounted tool is no longer in production, but you can still BUY IT HERE.
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Bryce Towsley has authored an informative article on Reclaiming .223 Rem Brass. Writing for Shooting Illustrated Online, Towsley confesses: “I’m a brass horder…. I end every shooting match on my hands and knees. If the rest of the competitors want to litter the range with their discarded cases, I see it as my civic duty to clean up the mess.” If you burn through a lot of .223 Rem ammo on the varmint fields or in multi-gun matches, we suggest you read Towsley’s article.
Towsley advises that you need to be cautious with range pick-up brass: “Range brass is full of dirt, dust, sand and debris that can be damaging to loading dies, as well as causing other problems.” So, range pick-up brass must be cleaned and then sorted carefully. Towsley explains that you should toss brass that is badly dented, and you have to make sure to remove the primer pocket crimp in military brass. This can be done with a crimp reamer or a swaging tool such as the Dillon Super Swage 600. The latter works well, but Towsley cautions: “For the swager to work properly, you must sort the cases by brand and lot, and then readjust the swager for each new lot.”
Trimming Quantities of Brass
Before loading, “reclaimed” range brass should, of course, be full-length sized and you should trim all the brass to the same length. “Cases that are too long can cause all kinds of problems”, explains Towsley.
We envy the system Towsley uses to trim brass. He has a Dillon Rapid Trim 1200B set up on the top of a single-stage press: “You simply insert a case into the shell holder and raise the ram to trim it instantly. The process is so fast, it almost feels like cheating.” The Rapid Trim is a very neat gadget — it even has an attachment for a vacuum hose to remove the cuttings. The photo at right shows a 1200B installed on a Dillon progressive press.
We definitely recommend you read Bryce Towsley’s Reclaiming Range Brass Article from start to finish. The article offers useful advice that will help you reload any rifle cartridge — not just .223 Rem range brass. Towsley also showcases many good labor-saving devices that can speed up and simplify the process of bulk rifle cartridge reloading.
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Lots of slots — that’s what you’ll find on the top of RCBS’s new Pro-Chucker 7 progressive reloading press. This thing has SEVEN (7) stations, which gives you great flexibility when reloading. You have plenty of extra slots for special dies such as crimp dies or powder-check dies. The 7-hole interchangeable die-plate (aka tool-head) is am impressive bit of engineering — it looks like the cylinder for a super-sized revolver.
Our friend Gavin Gear of UltimateReloader.com got his hands on one of the first production models of the new Pro Chucker 7 progressive press. Gavin reports: “This 7-station auto-indexing progressive is the ‘big brother’ of the RCBS Pro Chucker 5, and is built on the same frame. While it shares most of the same internals, there are a few differences”. Key differences include a seven-station shellplate and seven-station die-plate (vs. five stations on the Pro Chucker 5). In addition the priming system is slightly different and the Pro Chucker 7 comes with a much larger powder hopper.
Watch Pro Chucker 7 Unboxing Video:
To demonstrate the new features of the Pro Chucker 7, Gavin has produced an unboxing video that shows the components of the system. This is a completely different design than the RCBS 2000 system progressive press (which this editor owns). The Pro Chucker series 5 and 7 presses have a more compact frame and a more conventional, vertical column priming system. They don’t take up much more space on your loading bench than a turret press, yet they offer full progressive capability, creating one loaded round with every pull of the handle.
If you are considering purchasing a progressive press (whether green, red, or blue), you should watch the video and see the press features. Gavin Gear will demonstrate how the Pro Chucker 7 works with another video to be released in the near future.
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Starline Brass offers a series of videos with helpful reloading tips. Focused primarily on pistol cartridges, these short videos can help anyone get started with metallic cartridge reloading. If you load pistol rounds on a progressive, this video series is particularly helpful. The on-camera host is Hunter Pilant, son of Carroll Pilant of Sierra Bullets.
Preventing Double Charges
Tip: Use a bulky powder that fills your case more than half way with a correct charge. This will overfill the case if it is double-charged, making it very difficult to seat a bullet.
Tumble New Brass Before Loading the First Time
Tip: Tumble new pistol cartridge brass in used media for 30 minutes before loading for the first time. This will add enough graphite (carbon residue) to smooth case entry into dies. You can also lube the case mouths with graphite, or use spray lube.
Powder Through Expander — How to Eliminate Hang-ups
Tip: When loading pistol brass with a progressive press, sometime the powder-through expander is hard to remove, especially with short cases. There are two fixes — first, try deburring the inside of the case mouth on your cases. Second, the radius of the powder through expander plug can be modified to smooth entry and exit (see photo). Starline will do this modification for free.
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What can happen when the bottom-most primer in a primer feed tube goes off? A big bang, that’s what. Some or all of the primers in the vertical feeding tube can go off in a chain detonation. That’s exactly what happened to Dustin Ellermann, Top Shot Season 3 Champion. Scary experience, but thankfully Dustin was not injured. He writes: “Super thankful that I was wearing my Wiley X eye protection this weekend when I was reloading some .223 rounds. My press detonated nearly 100 small rifle primers. Shown here is the magazine feed tube. Not fun but it could have been much worse. Stay safe!”
When working with progressive reloading presses, you should definitely wear eye protection. Dustin’s chain detonation experience proves that — without a doubt. Remember you only have one set of eyes!
APS Strips — Alternative to Primer Tubes When you stack a column of primers in a single metal tube, you’re asking for trouble. As Dustin Ellermann learned, when one primer fires, the entire column can follow suit in a chain detonation. Thankfully, you do have options when it comes to primer feeding on a progressive press. RCBS developed an innovative primer system for its Pro-2000 progressive press. Instead of being stored in a vertical tube, primers are placed in flat, plastic “APS” strips, with a ring of plastic separating each primer. Moving horizontally, primers are never stacked, so the chance of a chain detonation is reduced dramatically. The re-usable APS strips are color-coded for different primer types. You can buy CCI “pre-loaded” primer strips, or you can insert any brand of primers into strips using an RCBS strip-loader tool.
RCBS Pro-2000 with APS Strip Priming System
AccurateShooter.com Editor Uses Strip Primers
This Editor owns an RCBS Pro-2000 progressive press (manual-indexing version). The RCBS strip-priming system was one key reason I selected the RCBS Pro-2000 over similar-priced progressives from Dillon and Hornady. I believe the strip primer system is safer, more positive, and easier to use. Before I purchased my RCBS progressive, I “road-tested” the competition. I loaded hundreds of rounds on each of four different progressives: Dillon 550B, Dillon 650, Hornady Lock-N-Load, and RCBS 2000. I was concerned about the primer feed tubes on the Dillons, and I found the RCBS rotary powder measure was much more precise (and easier to adjust) than the sliding bar system on the Dillon machines. The RCBS priming system was definitely more fool-proof than the system on the Hornady press (a first-generation L-N-L that had issues with primer feeding). After “test-driving” blue, red, and green brand progressives extensively, I settled on the RCBS Pro-2000. A decade later, I still think I made the right choice. I like the APS strips for big jobs, and I can also use them in the RCBS hand-priming tool (shown below). With the strips, its easy to prime 20 or 40 cases at a time, and then switch to another type of primer for comparison testing.
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Looking to start a new enterprise? How about entering a field where consumer demand greatly exceeds supply right now — the ammunition business. If you have $38,000 or so you can get your own automated ammo-making machine from Ammo Load Worldwide, Inc., an American-run business located in Lewiston, Idaho. There’s also an 11-station, computer-controlled “Mark L” rifle ammo machine that’s a bit pricier — $77,000 with accessories. Sure that’s a tad more expensive than a Dillon XL650, but with a Mark L you can produce three thousand .223 Rem rounds per hour with the push of a button.
Watch Ammo-Loading Machines in Action:
Mark X Pistol Cartridge Loading Machine (about $38,000)
For over 30 years Ammo Load machines have served ammunition manufacturers, commercial loaders, private shooting ranges, and numerous law enforcement agencies. The Mark X Ammo Load machine (for pistol cartridges) has a maximum production rate of just over 5,000 cycles per hour. Many users produce between 3,000 and 5,000 rounds per hour. The primary factors governing the quality and quantity of ammunition produced are the components (particularly the cases), the caliber, and the capabilities of the operator.
The Mark X Ammo Load machine for pistol cartridges has nine (9) stations: Case Check, Size and Deprime, Primer and Primer Disk Check, Belling, Powder Feed, Powder Check, Bullet Seating, Bullet Crimp, Final Sizing. There are checks (with shut-offs) for case feed, primer feed, bullet feed, and powder load. The Mark X comes complete with shell case feeder, primer feed tube, powder flask, and bullet feed tube.
Mark L – Automatic Rifle Ammunition Loader (About $77,000)
In 2009 Ammo Load Worldwide introduced the Mark L automatic rifle ammunition loader in .223 and .308. Many proven features from the Mark X pistol machine have been incorporated into the Mark L to provide precise and consistent rifle cartridge loading at approximately 3,000 to 3,600 rounds per hour. All of the sensors and switches use fiber optic technology to increase precision and reduce maintenance. The Mark L utilizes a 3-station powder drop; the manufacturer claims this maintains charge weights to within 1/10th of a grain.
Mark L Rifle Cartridge Loading Machine has 11 stations:
1. Sizing/Checking*
2. Mouth Flare
3. Priming
4. Primer Check / 1st Powder Drop
5. 2nd Powder Drop
6. 3rd Powder Drop
RCBS makes a fine progressive press, the RCBS Pro 2000. This Editor owns one. I can tell you it is very solid, and the strip primer-feeding system has proven virtually fool-proof, something that can’t be said about some competitive progressive presses. I also believe the micrometer-equipped powder measure is superior to the Dillon alternative. Nonetheless, Dillon still dominates the progressive press market. One reason is that Dillon has long offered a reliable case-feeding system, and GSI International and Gaspari USA offer after-market bullet feeders for the Dillon 650 and 1050. Until now, with an RCBS Progressive, you needed to manually insert a bullet into each case. Well, at SHOT 2009, RCBS unveiled a new bullet-feeding system.
RCBS says its new automatic bullet-feeder will work with Dillon (blue) and Hornady (red) progressives as well as the RCBS 2000. The unit mounts to a sturdy vertical support, with a flexible tube that connects to the bullet-seating station. It looks well-designed, and during a demo by RCBS manager Kent Sakamoto, the bullet-feeding system worked flawlessly. Kent showed us the pistol-bullet feeder, but a second version for rifle bullets will be offered by mid-2009. The rifle-bullet feeder should be just the ticket for varminters who need to load large quantities of .223 Rem, 22-250, or .204 Ruger rounds. Sakamoto explained that the automatic bullet feeder can significantly boost your reloading output whether you have a blue, red, or green progressive press.
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When you stack a column of primers in a single metal tube, you’re asking for trouble. As Dustin Ellermann learned, when one primer fires, the entire column can follow suit in a chain detonation. Thankfully, you do have options when it comes to primer feeding on a progressive press. RCBS developed an innovative primer system for its Pro-2000 progressive press. Instead of being stored in a vertical tube, primers are placed in flat, plastic “APS” strips, with a ring of plastic separating each primer. Moving horizontally, primers are never stacked, so the chance of a chain detonation is reduced dramatically. The re-usable APS strips are color-coded for different primer types. You can buy CCI “pre-loaded” primer strips, or you can insert any brand of primers into strips using an RCBS strip-loader tool.
Bryce Towsley has authored an informative article on 
Trimming Quantities of Brass
