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BTW: Gavin, I visit you site often, would love to see how you would do it without modifying the press, I've seen it done 3 ways, the slight notching like in this thread, another user drilled a hole on the turret head exactly like a Dillion head would be, he used the logic and choose station 3 because the pressure points would be at station 1, none at 2 with powder fill, no pressure Dillion PC in 3, nothing in 4, and crimp/taper in 5, although I think that you could get away with the hole drilled next to just about any of the stations and not weaken the press like he thought it might do,
http://www.youtube.com/user/FriedChickenBlowout?feature=mhum#p/u/8/nXMD_Km-AM0 is a link to the user who drilled his hornady through the top. By the way, Fried Chicken Blowout DOES NOT like Hornady, but sure did a good job of getting the Dillon powder check in his system. Seems some people LOVE RED, others LOVE BLUE, I wont even go there.
And then of course, there are a couple of people that have done what you are saying, without modifying the press at all. ->
http://www.youtube.com/watch?v=F0z-isyIPG8
I choose to do mine like the OP here, a round file and some work cut the grove real nice, however, I dont think that I made my groove as big as the original OP, because when I used the original cap screw and nuts, the top nut caught the edge of the groove. So I went down and bought some 10/24 threaded rod and nuts and threaded the rod into the original Dillion shaft with locktite and as deep as it would go, so there is no movement, but also no need to tighten down at the end of the shaft, then used 1 1/4 fender washer with two 10/24 nuts to hold my washer at the correct depth. I can tell you, understanding how to use the Dillon device before attempting this helps, as I kept messing with raising and lowering my die in the press, then took some time and realized you adjust for different powder heights by adjusting the height by messing check rod sleeve.
I come back to the original OP with my question again, as it seems that the powder check rod can camber out and when the case is coming up to it, the case rim pushes the rod up rather than than entering the case, and of course that sets it off as well. I basically notice that I can rotate the check sleeve and rod until it lines up entering my cases smoothly and it stays in that position for my testing (I haven't even started loading yet, just getting each part working and started with this part). Did you experience this? I guess I can ask Gavin if he experienced this in the Dillon, as it seems to me the same thing would work on the Dillon the same way, the way the case raises in the press and meets the rod in the Hornaday is the same as the Dillon and every other press out there, so maybe its just dealt with the way I am messing with it, fiddle and find the sweet spot and it will just stay there?
Again, OLD thread, but the original OP is still around, I see his youtube videos, and posts. So I don't think he will mind it coming back to the top. I think I am going to like my RCBS lock out, but it doesn't work with riffle, so until they fix that or Hornaday comes out with something other than a visual powder cop, people are going to be doing this..