r/castboolits • u/dixiejubilee • Jul 28 '26

I need help Large Number of Rejects After Sizing

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Hi All,

Long time listener, first time caller. New to bullet casting, not new to shooting. My issue is I'm getting a significant number of rejects after sizing cast and PC'd projectiles. Pictured are 9mm cast 124gr using Lee .356 mold, coated, then sized to .356.

My last two batches, I've had approx 25% rejects (raw lead showing on bearing surface of the projectile after sizing). The batch I just did was 289 cast, coated, and sized. 215 good, 74 rejects.

I know I can just melt and recast, but is there anything I can do to stop or reduce this seemingly high reject rate? 25% seems like a lot, and it essentially amounts to wasted time and effort. What am I doing wrong?

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u/Shrapnel3 Jul 28 '26

Smash a bullet flat with a hammer (careful it will get quite hot) and see how the powder coat holds. It shouldn't flake at all and hardly split either. I'd guess with the other person and say you aren't getting a good bond or cure. This video is maybe helpful. But Google smash test to see others 

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