Yeah sometimes it just goes that way, no rhyme or reason
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I found with my hornady. 243 die. I had to polish the expander ball with wet n dry sandpaper. Went in ok bit tight as hell to get back out, no matter how it was lubed. The other sizes I have are fine.
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Yeah, mine it's getting the case started in reverse. I assumed the expander ball was the problem, so took the decapper pin out and ran it in until the inside of the case head was almost touching. No way it was anything to do with the case getting removed until the neck was almost out. Still damn near tore the next rim off. I can't work it out with the Hornady dies. I bunged mine into the ultrasonic cleaner, dried them off with compressed air and spray lubed it to stop it rusting. Then wiped imperial wax all over the insides with a cotton bud, pricked out the air relief hole to make sure that wasn't gunked up and reassembled it. Not a lick of difference. The expander ball is not the issue, it's something with the die body itself and the getting the case moving on the down stroke of the press ram. They need a noticeable amount more force on the way up - but it's starting the case moving back down and out that gives the issues with stuck cases (I don't want to use the work extraction here but that's it in a nutshell).
I've never seen a press ram bust like that though - that's a new one for me. I've seen a shellholder where the rim recess has been bent up and buggered, but tearing the ram apart is a good effort. I'd definitely send a picture to Lee and get them to comment - would not be surprised to see them make good on it. They are pretty bloody good on that front!