Here is a DIY on how I expanded and re-sized my swaged slugs to fit a larger diameter barrel bore. The swaged slugs were NSA .457 HP-DB 220 & 240 grainers' that I made into gas checked slugs that fit the large bored AEA Challenger barrels. Keep in mind that this re-sizing process can be used with any size of slug, including cast, by adjusting the size of the punch that is being used to squish the slug's length and expand the shank a few thousandths of an inch.
For these particular slugs I used a long strait punch .125" diameter, just smaller in size than the inside of the hollowpoint cavity. I tapped the punch squarely with a hammer until satisfied with the resulting reformation to the skirt. The more you tap, and harder, the more it smashes the lead. The key is to figure out the amount of hits and force used to get the right size without overdoing it. (Once I figure out the ideal slug size through testing I will make a punch that I can put in the Lee press and adjust the length to essentially do the work of the hammer.)
Then I ran them through a Lee press with a .457 sizing die that I opened up and polished to the barrel's .463" i.d. I opened up the inside of the Lee sizing die using a hand drill and a drill bit shank wrapped with wet or dry sandpaper until it measured close to the size I needed. Then I polished it using the same method, with finer grit paper.
I made two different sizes of slugs based on how many times and how hard I hit the punch to test for accuracy. So far it looks like the harder hit slugs (shown in the pictures on the right) that deforms and resizes both the top and bottom may be more accurate, as those are the ones actually touching the grooves of the barrel in the front. Whereas the other's are just riding the barrel lands and may not be coming out of the bore square. (I have only had them inside of ten yards and through ballistic gel now; long range testing to come later.)
For these particular slugs I used a long strait punch .125" diameter, just smaller in size than the inside of the hollowpoint cavity. I tapped the punch squarely with a hammer until satisfied with the resulting reformation to the skirt. The more you tap, and harder, the more it smashes the lead. The key is to figure out the amount of hits and force used to get the right size without overdoing it. (Once I figure out the ideal slug size through testing I will make a punch that I can put in the Lee press and adjust the length to essentially do the work of the hammer.)
Then I ran them through a Lee press with a .457 sizing die that I opened up and polished to the barrel's .463" i.d. I opened up the inside of the Lee sizing die using a hand drill and a drill bit shank wrapped with wet or dry sandpaper until it measured close to the size I needed. Then I polished it using the same method, with finer grit paper.
I made two different sizes of slugs based on how many times and how hard I hit the punch to test for accuracy. So far it looks like the harder hit slugs (shown in the pictures on the right) that deforms and resizes both the top and bottom may be more accurate, as those are the ones actually touching the grooves of the barrel in the front. Whereas the other's are just riding the barrel lands and may not be coming out of the bore square. (I have only had them inside of ten yards and through ballistic gel now; long range testing to come later.)
