Part 1
(WARNING NOTE: For the work described below I used my bolt rifle, which has a 1:16" twist barrel with 0.451" grooves. Pressures for reliable semi-auto operation are not a concern. If you try to duplicate what I did, bad things may happen from using different components, different techniques, and different rifles. Be careful. Don't forget that this information is coming to you on the internet.)
This last segment of the 185-grain SWC story introduces no new techniques. It's just a follow-up to Chapter 7 which was about crimping (LINK to Chapter 7). That chapter described how side crimping seemed to solve ignition problems of a straight case full of powder behind a light bullet. With 53.5 grains Lil'Gun behind Hornady's Totally Encapsulated 185-grain SWC bullets (#45137), 8-foot instrumental velocity was 2980 fps. This was really close to the objective of the entire series of trials: 3000 fps.
Below are two concluding exercises. I wanted to find what velocities and problems might result from squeezing a bit more powder behind the 185-grain SWC bullets, and what might be their accuracy.
I used 2X- and 3X-fired cases, and prepped them using Hornady dies with FL resizing and minimal case mouth expansion. I loaded 53-55 grains of Lil'Gun in 0.5-grain increments. Primers were Win SRs.
It was not physically possible to use more than 55.0 grains. For the 54.0, 54.5 and 55.0 loads, powder was trickled in with a 2-foot drop tube, and seating the bullet required heavy compression. To try to gain powder space by seating bullets less deeply wasn't possible; the C.O.A.L. has to be 2.000 inches or less to permit the side-crimp to be applied without distorting the base of these short bullets.
The crimp in these rounds not only served to provide the needed resistance at the start of ignition, but also to keep the compressed powder from pushing the bullet out of place. Appearance of the loaded rounds is shown on another thread: (LINK to image).
After side-crimping, the Hornady taper-crimp die was applied, but it did little. What looks in the image like belling or flare at the case mouth is an illusion. The case mouth was flat against the bullet, and mouth diameter finished at 0.476".
At the range, the center of the chrono screens was eight feet from the muzzle. Air, ammo & rifle temperatures were 48 degrees F. Recorded velocities were:
charge - - - trial 1 - - -trial 2
--------------------------------
53.0 gr - - - 2950 - - - no rd
53.5 gr - - - 2964 - - - 2971
54.0 gr - - - no rd - - - no rd
54.5 gr - - - 3057 - - - 3003
55.0 gr - - - no rd - - - 3050
(A month later now, the resulting shoulder bruises I reported elsewhere (LINK) have finally disappeared.)
There were no obvious signs of excessive pressure from any of these rounds: no sticky bolt lifts, no flattened primers, no radial expansion of case heads, no extrusions of case heads into ejector slot, etc. As noted before, I know that looking at these is the equivalent of reading tea leaves, so I may have been in trouble and not even known it.
The crimping groove was ironed out almost completely. It could be seen as a narrow band on the case exterior, and barely could be felt with the fingers.
So, about a year after starting the project (with lots of interruption), 3000 fps showed up on the chronograph readout, with apparent safety.