reloaded .40 caliber bullets brass bulge.

[Jekemi]

I reloaded some .40 S&W this morning. I flared the brass, and loaded the bullets. The bullet seating die pressed the bullet to the right OAL. The sides of the brass looked perfectly straight and measured .40 from top to bottom. Then I used a crimping die and it did a nice job of crimping the brass around the bullet. BUT there is a slight bulge to .42 right below the crimp mark. I really didn’t notice it until I did about 30 of them. So, I have a few questions:
1.   Will .42 fit the chamber (I don’t have the gun yet so I can’t manually check it)?
2.   Why did it do this?
3.   Did I have the crimp set too tight, which caused the brass to bulge slightly?
4.   If I pull the bullets do you think the sizing die will resize the brass correctly?

[JimmyHoffa]

Is the crimping die separate from the bullet seating die?  I've crushed more than a few by having the crimp set too early.
I think if you pull them and resize it should work.  Just use enough lube and set the decapping pin high enough to not lose all the primers.

[Jekemi]

Here's what I have learned.
1. the roll crimp die, which is the one I have is designed for cannelured bullets
2. the bullets I am using are non-cannelured
3. I should have gotten the Lee factory crimp die (which I have since ordered)
4. This should take care of the problem
5. in addition, I need to back off on the crimp so that the case just barely crimps over the bullet, making sure the OAL is within the recommended parameters. This will prevent the bulge at the top of the case. At least that's the theory.

Thanks for your advice.

[woodswalker]

You are mostly there, I'm personally unsure of the Lee Factory Crimp die as it deforms the bullet, I use a Taper Crimp for my .40 and 10mm.  No issues with that with either cannelured or non-cannelured bullets.  I will seat/crimp in the same operation after a few rounds of careful set up.