Stuck 30-06 cases in sizing die

[EFoat]

My family has a problem, and after doing some research I realize that it is not unique. For Father's day, my brothers and I bought our dad a new gun chambered in 30-06 Spfld. Since we reload for all of our other guns (.223, .260, .270, 7mm, etc.), we bought the dies for the '06 as well. The problem occurs with the sizing/decapping die.
New unfired shells do not get stuck in the die and cycle through effortlessly. However, after the shell has been fired, it gets stuck. We tumble/clean and lube the brass before sizing. My dad broke 3 sizing dies-the sizing ball shears off or the shaft bends inside the case when trying to extract the shell from the case. It seems to get stuck on the inside at the shoulder of the case, not around the outside circumference of the shell. Two dies were LEE dies and one was RCBS. Two broke with a LEE wax lube, the last one with One Shot. It does not take unusual or unreasonable force to insert the shell into the die (compared to all other loads we have made for our other various calibers), but the shell refuses to extract. How do we fix this problem?
We will soon buy a new die (LEE) to try a fourth time. We are going to try cleaning out the inside of the shell with a brush and solvent and using a new lube (perhaps a toilet bowl ring-I have heard that works great!) If it gets stuck again, we will be shipping it off to LEE to ask them what the problem is.
I would definitely appreciate any help/advice from the members here at THR!
Thanks!

 

[1KPerDay]

I just started reloading a couple of months ago but I did stick a .30-06 case in my Lee FL sizing die the first try.

What I learned:

1. Don't use one shot.
2. Clean the die.
3. Get some imperial sizing wax
4. Be sure to lube inside the necks of the cases
5. check the diameter of the sizing ball and sand/polish it down to .002-.003 smaller than actual bullet diameter using fine emery paper and a drill.

It sounds to me like the expanding ball might be too big/rough, and/or you're being to aggressive on sizing. Are you using full length or neck sizing dies?

 

[EFoat]

We are using full length sizing dies.

 

[dawico]

It sounds like your expander is set too high or low. Too low would bend it, and too high would pinch the case between it and the shoulder of the die. Since you are experienced, I am guessing you know what you are doing. I have had no problem with Lee Dies for the 30.06 and fired brass.

 

[popper]

I would expect the rim to be pulled off before the decap shaft breaks. I have an RCBS .308. the ball has sharp shoulders. If it is set too high or forces a "thick shoulder ring" it will really catch on the way out. Hornady has a tapered ball, so it wouldn't catch as easily. As you say you reload for other bottle neck cases and used several die. I'd sent some brass back with the die, if I sent the die back.

 

[Sunray]

What ammo/cases are you using?
Never heard of an expander button breaking off. The rod will bend if it's set up to go down too far and the case is rammed into the die though. Hits the bottom of the case. Cleaning the inside of the case won't help.
Considering it's happening with multiple dies and two brands, it's something in how the dies are being set up. An FL die(and all your dies) should be set up so the shell holder just kisses the bottom of the die with the ram all the way up.
If you're using the sizer die to decap, the rod should be set up so the pin is down far enough to just pop out the spent primer and no more. Lubing the expander button(I just screw the case mouth into my lube pad. No wax or sprays for me.) will help.
You shouldn't need to buy another die. Contact Lee first. They'll likely want you to send 'em the die. RCBS will just send you another part with a phone call.

 

[ArchAngelCD]

Just a guess but I would try using Imperial Sizing Wax and like said above, make sure you lube the inside of the neck. I also use Lee dies for reloading the 30-06 and have no problems. Double check your die adjustments because this is happening with 2 different company's dies.

 

[Slamfire]

I have found spray on lubes to be inadequate especially for small base sizing.

I highly recommend Imperial Sizing wax or RCBS water soluble.

I use the RCBS more often as it washes off the cases in hot soapy water.

 

[gamestalker]

To have found the one in a million resizing die with such a serious spec issue is possible. But 3 in a row that are breaking as a result? That alone is really bizzar. I can't even imagine what it takes to break a die. Something isn't right here.
You said you have been loading .270 win. among other cartridges, but regarding the .270 win, it might be possible that brass, is getting mixed up with the 30-06 and causing a problem. Then again, I have regularly used 30-06 for .270 brass and visa versa without issues. They resize with little if any noticable difference through the parent die.

 

[bigedp51]

Can you post photos of your fired cases, do these fired 30-06 cases look different at the neck shoulder junction area than a unfired cartridge. What your describing of breaking decapping rods is strange because as stated above brass is softer than steel and you would think the rim of the case would rip loose before a steel decapping rod would break.

Do you and your father have the same experience at reloading or is this the first time for your father. Something they taught us in QC as Inspectors....

"97% of all errors are human errors and only 3% are actual mechanical failure errors"
Murphy's law "Anything that can go wrong will go wrong".

 

[ranger335v]

"My dad broke 3 sizing dies-the sizing ball shears off or the shaft bends inside the case when trying to extract the shell from the case. "

No case lube can bend/break an expander nor can withdrawing the expander from a case bend/break an undamaged decap stem; only having the expander set so low so it hits the solid web can do that. Adjust the stem so no more than about 3/16" of the decap pin extends below the mouth of the die and all should be well.

 

[jleyring]

It sounds like your expander is set too high or low. Too low would bend it, and too high would pinch the case between it and the shoulder of the die. Since you are experienced, I am guessing you know what you are doing. I have had no problem with Lee Dies for the 30.06 and fired brass.

Thats what it sounds like to me.

 

[mrbro]

Where did the brass come from and what is the headstamp?

 

[Sensai]

How old was that Lee die? The reason I ask is because all current Lee sizing dies use a one piece decapping pin/ expander ball rod. It's held in by a collet that will let it slip if too much pressure is put on it. I don't see how it's possible to break the thing without getting really creative!

 

[langenc]

So many questions-so few answers.

Lube cases w/ Imperial and raise the decapping stem/ball. Lube the inside of the case mouth to keep from stretching the neck when the expander ball comes out.

 

[1KPerDay]

So many questions-so few answers.
Lube cases w/ Imperial and raise the decapping stem/ball. Lube the inside of the case mouth to keep from stretching the neck when the expander ball comes out.

If you read the thread all of your suggestions have been posted.

 

[ArchAngelCD]

I have found spray on lubes to be inadequate especially for small base sizing.

I highly recommend Imperial Sizing wax or RCBS water soluble.

I use the RCBS more often as it washes off the cases in hot soapy water.

Imperial Sizing Was is also water soluble although most times I just wipe it off with a old washcloth.

 

[EFoat]

WOW! This was my first post, and I did not expect such a quick response from the folks of THR! Thanks all! I admit, I was browsing your forums looking for an answer to another question, and remembered that my dad had problems with his '06, so I figured I would throw the question out there. Unfortunately, my dad has the reloading setup at his house, so I can't implement your suggestions as soon as I would like.
1KPerDay-Thanks for the suggestions. We'll definitely try them all.
dawico-I will have him check the expander, though I don't think that is the issue. It's worth a second look.
popper-If we need to send the die back, we'll send some brass as well. Great suggestion.
Sunray-We are using new Remington brass. We will have to look at the setup again. Your suggestions for die setup will be put into practice.
ArchAngelCD-We'll try the wax and check the die settings.
SlamFire1-Thanks for the lube suggestions.
gamestalker-.270 and '06 brass have not been switched, so this is not the issue.
bigedp51-My dad has more reloading experience than I do. I am just recently getting into it to save on ammo costs. He has always reloaded (6-7 yrs or more now) for all the family's rifles and handguns. I'll try and get pictures.
ranger335v-We'll check the set up. Thanks for the advice.
mrbro-We bought the Remington brass at our local sporting goods store. He has also tried reloading once-fired factory-loaded brass of the Remington flavor. I don't have it with me to check the headstamp.
sensai-All three broken dies were no more than 5 years old.
langenc-So many questions, so little answers: my dad works swing shifts and it is hard to get in touch with him at times. We will be taking our wives on a vacation for 2 weeks this Friday, so I will have plenty of time to ask these thorough questions!
As I said above, he has the reloading setup at his house. I wasn't with him when the dies broke, but fully trust that he had all dies properly set up, as he has never had a problem in the past when reloading for our other calibers. It is my understanding that he can cycle through and load brand new unfired brass, but not once-fired brass from his gun. I don't know if he can load once-fired brass from another '06. My initial thought, considering that he can work through new brass and on the same die settings cannot work through once-fired brass, that may be indicative of an issue in the chambering of his gun, that perhaps there was an issue in the machining of the chamber. This also may fit the scenario of breaking dies from two different companies-it would be hard to set up the dies incorrectly 3 different times on three different occasions and recieve the same results, namely 3 broken/stuck dies. However, there is no obvious visual difference between the fired and unfired brass. A way to test this theory perhaps is to try and load fired brass shot from another '06.
We'll be on vacation for two weeks, so I will keep you all updated after that.
Thanks again for all your suggestions and advice!
Take care!

 

[mrbro]

Don't worry about the head stamps, they're not needed.

he can cycle through and load brand new unfired brass, but not once-fired brass from his gun

If he is sizing the new brass, this rules out the dies and the adjustment process.

that may be indicative of an issue in the chambering of his gun, that perhaps there was an issue in the machining of the chamber.

I can't think of anything chamber related that would cause this.

We'll be on vacation for two weeks, so I will keep you all updated after that.

Enjoy your vacation, I doubt this problem will fix itself before you return.