I hate the cliche "welcome aboard"
so I will just say I am glad to see you here, Chris. Heh--"shadowwood" is the name of a upper-end housing subdivision near here; that was a real Freudian slip of some sort. Last June, you and Darwin-t became my reloading heroes when I tackled the Load-Master setup again. In addition to simply seeing the various setups being done, I thought the STP lube recommendation was pure genius. The demos of successful, high-volume production really spurred me on.
In the big picture of this setup process, I think the best paradigm for setup "starts with the beginning"--e.g., get the #1 (resizing / decapping) at the right height, and then proceeds forward. In addition to this "one-step-at-a-time approach, there needs to be tweaking done to the entire subsystem you're working on."
about die setup tweaking:
I went through an extended-tweaking process when I finalized my die setup. The primer-resizing die had been added, and I (much earlier) done the appropriate primer-anvil screw adjustment. And, by this point, I had the separate decapping / resizing dies in place. Further, I had gone to separate seating and criming / final sizing by adding a FCD.
As I tried a short run (one tubeful of cases), I found I still had the erratic LOAs problem, and the last five cases went to perhaps -.005 (or greater) variance. That's not good if one is loading MAX load cartridges, as I am planning to with 38 Special.
The solution to this (other than accepting erratic LOAs of generally-inconsequential difference) rests in getting "equal" pressure on the shell plate for all dies. I found that when I added the "4-die configuration" (the separate seating and crimping), the LOA change was minimized to perhaps +- .002. To get to that variation, I backed up all the dies and started over.
Begin with the first die station setup, and follow Lee's direction for a "plus-1/4" setting.
IIRC, the most successful setup came by removing the #1 / decapper die (after putting down witness marks) and then putting in the #2 decapping die, setting the "plus 1/4" to the same pressure on the upstroke. I then reinstalled the #1 / decapper die and confirmed no change in feel.
With these two dies as my starting point, then, I reset the PTED, the seater, and the crimper / sizer, working on them one at a time and checking the "pressure" on the downstroke.
The PTED deserves special attention to using a "typical" case in place and setting the die height by feeling the initial contact with the case mouth. Then I could tweak the expander setting to my liking.
As I worked my way to the seater-crimper die (now adjusted to provide only seating), and then to the FCD in the 5th / last station, the setup became a bit more complex.
As one adjusts the last two dies, it becomes necessary to "balance" the shell plate pressure from dies one and two with the shell plate pressure from dies four and five. I did this simply by careful observation of the shell plate and die four (then die five) deflection. Again, IIRC, I even went back and "backed up" dies in stations one and two--only a bit, perhaps 1/32 of a turn.
All this adjusting was done with cases in place. As a result, I ended up with many cases in various stages--decapped, decapped-and-sized, decapped-and-sized-and primed, etc., etc.
The end result was is that the Load-Master now has an extraordinarily smooth feel to it, with no unusual "quirk" in any given process. The LOA is typically +- .0015 in production when all die stations are filled, and the LOA only shortens to -.002 or -.003 as the last cases work their way to then catch bin.
The above recitation is an extremely verbose description, but at least it is down on paper, so to speak. I'll post it now and edit it a bit later.
Jim H.