I am reloading 38 short colt starline brass using 160 gr coated bullets .358 in diameter. They are causing my cases to bulge and therefore they will not completely enter the case checker.
I have been using 160gr with .357 diameter with little problem.
Is there a secret to keeping these things from bulging the case.
Your assistance will be greatly appreciated.

I load the same exact thing, I can double check when I get home but I am almost positive I use a Lee Factory Crimp Die

I use a Lee Factory crip die in 9mm. If you have a case guage, see if your loads drop in all the way. Mine lack about 1/4 inch going all thev way in the case gage.

You mentioned that your reloads will not fully enter your case checker. Will they chamber in your revolver? If they do, you don't have a problem. If they won't chamber in your revolver, your choices would be:

1. Use .357 bullets instead of .358.
2. Use the Lee FCD as suggested.
3. Use thinner wall brass (probably not findable).

I see the same bulge in my .38 Special reloads with .358 bullets and have never had a problem with chambering in a variety of revolvers from 1899 to the present.

I normally use 357. This was my first time to use 358. They will chamber so I will may use them for practice but use 357's for competition because I have such good luck with them. I do use the lee FCD. Thanks for your info.

Never heard of a 160 grain bullet - all mine are 158 grain if they are cast or jacketed. Where would one buy a 160 grain bullet?

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S&WHF #946
S&WCA #3824

Bang and Clang/Bayou Bullets for a couple. They are coated bullets.

Interesting. I use Bang and Clang but I normally use this bullet:

158 grain 38/357 and 9MM SWC sized 0.356-0.358 Coated - Bang and Clang LLC

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S&WHF #946
S&WCA #3824

Have you done a plunk test? I have had a few problems with handloads that would not pass a gauge test, but fed and fired quite well, no problems...

I really like the round nose bullet. I think the 358 diameter will work better in the 38 special brass. I will load some of those and see how they run.

If the rounds will chamber fully, I wouldn't worry about doing anything.

My gauges are CARTRIDGE LENGTH gauges from Wilson and are not that great for chambering testing. I plunk in the barrel before I reject a loaded cartridge that won't fit in the gauge.

Does anybody have gauges that are made for chambering testing?

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"He was kinda funny lookin'"

For the short colt I always loaded 148 gr. Berry Bullets. 158gr. I found was to heavy for the short colt. Plus to load easier I load 148gr 9mm rounds.

Mine is a Wilson also.

Is the bulge even all away around the cartridge?

Yes it is.

Thanks for all your responses. You helped me to decide a reasonable solution. I plan on resizing the 358 to 357 and stick with what I know works. Seems I’m always tinkering to my own destruction. If it ain’t broke don’t fix it!!

I load 125 gr. RN. I think they're .358 but not sure. 125-135 gr was the original weight for this cartridge. 158 gr is the original weight for 38 Spl. which is a much larger case. I'll have to look but I think I use a Lee FDC also.

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That's just somebody talkin.

Just where is the bulge in the case? If it is at the base of the bullet then don't seat them so deeply. If it is the entire bullet shank then use .357 bullets!


Finally, just why are you using a cartridge gauge to check your ammunition? If the cartridges freely enter the chambers of your revolver then they are fine. Throw the damned case gauge away, you don't need it!!!!! The "plunk check" is intended to check the ammunition in the gun it will be used in, you don't plunk check in a case gauge!

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Gunsmithing since 1961

You said you had little issue loading with .357d (coated?) 160gr bullets.
I would guess that the .358d Coated bullet is the main culprit.


Not knowing exactly where the bulge is,,the use of a 9mm Lee FCDie may
be bulging the brass as well with the oversize bullet.
A 9mm bullet is generally .356d
Adding the extra .000's to the equation and then using a smaller crimp die can't be a good thing.