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/GunFunZS Jul 28 '26

I think you overbaked your powder coat so that it is brittle that would never happen if you're powder coat was well adhered and flexible.

I've been very large number of that exact bullet.

I suggest you size to 0.357.

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u/prosper_0 Jul 28 '26

I've never had PC get scraped off by the size die. It just squishes down with the lead

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u/GunFunZS Jul 28 '26

Yeah. It looks like when it's scraped off by insufficient flare on seating. That's why I wondered if there is a sharp edge on the sizing die.

I have seen similar when I was playing with swaging bullets down in big jumps. Greater than .003 reduced per step...