by pitted bore » Tue May 03, 2011 3:17 pm
snyder1941-
I assume by "Die #4" you are writing about the fourth die in the Hornady die set -- the taper crimp die.
It may or may not be true that "the use of die #4 is critical from a safety point of view" as you state. One critical point of safety is that the reloaded round conform to dimensional specifications. If the mouth of the case has been belled or flared with the expander die, then the taper crimp die is needed to remove the bell or flare. Otherwise there could be problems with feeding or seating of the cartridge properly in the chamber, which might contribute to an unsafe condition.
When reloading, if seating the bullet results in a bullet held firmly in the case and in a case mouth with no flare that measures about 0.476" OD as Hoot indicates, then there may be no need to use the taper crimp die.
The other safety issue concerning the taper crimp die #4 might involve insuring the bullet is held firmly in the case. If the bullet is too loose, there might be some problems with incomplete powder ignition or hangfires, which can be dangerous. If the bullet is loose after being seated, then a crimp of some sort is needed.
Checking for "proper neck size" is not really a problem with the Hornady die set in my experience. After resizing, check to make sure the bullet can be seated without crumpling the case. Measurement is usually not necessary at this stage. If the neck is too small, then use the expander die to bell the mouth the minimum needed to permit seating the bullet. Use of the taper crimp die is needed to remove the bell from the mouth. It's at this point in the process that the OD of the mouth is measured, as Hoot points out.
If this isn't clear, please ask again. As Wildcatter points out, safety in reloading is the paramount concern.
--Bob