Converting .38 Special Brass to Accept Large Pistol Primers

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One gap in my preps that has come to light in the aftermath of this year's panic caused by COVID19 and civil unrest is my insufficient stash of small pistol primers. I have around 2500 - 3000. As you are no doubt aware, small pistol primers are currently unobtanium at anything resembling a reasonable price.

In contrast, I have at least 5000 large pistol primers, which I primarily use for .38-40, .44-40, and also Magtech brass shotshells.

One cartridge I load for is .38 Special. I have thousands of .38 Special empties, so about a month ago the thought occurred to me that I could convert 50 - 100 to take large pistol primers.

If nothing else, it would make an interesting proof of concept for expanding my options if the situation becomes more dire.

In doing a bit of online research, I learned that there used to be .38 brass produced with large primers.

For anyone considering emulating this, I strongly suggest that (a) you do your own research and reach your own conclusions as to safety, and (b) do this only with modern, solid-head brass.

To convert the cases to accept LPPs, I employed a .210" diameter chucking reamer in my 7x14 mini-lathe. To ensure that I reamed all the primer pockets to the same depth, I added a stop collar to the reamer. The collar is made from a piece of 1/2" diameter 6061 aluminum rod and held in place with an M4 set screw from my miscellaneous screws bin.

reamer-stop-collar.jpg

To use it, I chucked deprimed a .38 Special case in the lathe and held the reamer in a drill chuck in the lathe's tailstock.

reamer-lathe.jpg

I found that because of the small clearances, brass chips built up between the head of the case and the collar. I had to withdraw in several times per case to clear the chips with a brush and pick. It was slow going.

But eventually, I converted a total of 10 cases to accept large pistol primers. To test, I seated CCI LPPs. They seated easily, maybe a little too easily. It might be better to use a .209" diameter reamer because .210" is the maximum for large primers.

38-LPP.jpg

I loaded the modified brass with 4.4 grains of Unique, a CCI LPP, and a .358 160 grain LSWC from Matt's Bullets. I also loaded another 50 in unmodified brass using Sellier & Bellot SPPs.

The round on the left is an unmodifed case. The 2 on the right are modified.

38SP_SPP_LPP.jpg

I was able to shoot the .38s with LPP converted brass yesterday, along with other .38s that were the same except for using SPPs. I fired them in a Ruger Police Service Six chambered for .357 Magnum. They worked fine and were indistinguishable from the ammo loaded with SPPs. So, as far as I'm concerned, this proof of concept was a success.

I did manage to source a couple thousand more SPPs which will arrive in a few days so I do not plan to convert any more .38 brass to take LPPs, but it's nice to know that if I need to, I can, and they will work fine.
 
better to use a .209" diameter reamer because .210" is the maximum for large primers.
Good idea as the SAAMI minimum is .2085"

The web thickness is the same for both. A old balloon head 38 may be a problem.

After the brass is converted, add in machine time & labor, about $5 per unit cost ? :D
 
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I found that because of the small clearances, brass chips built up between the head of the case and the collar. I had to withdraw in several times per case to clear the chips with a brush and pick. It was slow going.

I have a flash hole uniformer that does that, too. It has a limiting collar built in, and the brass chips pack up in it during use and you have to pick them out after every case... quite slow, for very little benefit, if any.
 
Very interesting. On a similar note, wondering if it would be possible to convert to .209 shotgun primers for a low pressure round?
 
Very interesting. On a similar note, wondering if it would be possible to convert to .209 shotgun primers for a low pressure round?

I am 99% sure there isn't enough meat in the head of a pistol cartridge to convert it to take 209 shotgun primers and load them with powder. It might be possible to use them for something like wax or hot glue bullets, for indoor shooting.

I'll leave that project for someone else, though.
 
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