Lee Expander Die Sticking in Case

[kenlee]

The Lee expander die is adjusted by lowering the body until you get the flare you want, then you lock with the nut.

I was taught to flare the case sufficiently to just start a cast bullet by 1/16", and no more, beyond the chamfer on the bullet base. This amount of flare is barely perceptible. Is this correct? With my old RCBS dies you could split a case with a badly adjusted expander die - I did a few. I was taught to not flare the case at all for a jacketed head although I've never loaded them. I won many a medal in the past with my model 14 and ammunition loaded this way!

I have reset the die to be certain. It sticks significantly well before any flare has been achieved. The free movement of the plug inside the die is about 3/8".

I have next removed the plug and tried it manually in the mouth of a sized case - it will barely start with significant hand pressure.
The inside dia of a sized case is .353" and the expander plug starting dia is .355". Two thou is two thou but on soft brass it's hardly a force fit. This again suggests the surface finish of the plug.

When I get the flare, as defined above, the die base is virtually in contact with the shellholder. If they were .38 dies there would be a bigger gap with the .357.

I know lubrication makes sense (there's joke there somewhere!) but with straight cases and good dies I've never found it necessary, leaving aside the contamination issue. I am very grateful for the ideas on lube, they will be very useful when I graduate up to .308 or similar.

[dromia]

You are flaring correctly, lube in this case (no pun intended) should not be necessary.

Just polish up the expander plug and you should be good to go.