There is NO WAY you can ever size all the way to the rim....as you said, there's an area at the base of the brass that the die can never contact.
What Bib said. As the casing sits inside of a shell holder, how would one think that the sizing die could sneak down inside the shell holder to do its job all the way to the case rim? Physics(ally) impossible. I also have experienced a failure to fully seat cartridges in the chamber due to the bulging just up from the case rim, but it was too long ago for me to remember which gun/which caliber it was. I also remember that when they were tight, I simply pushed them in harder, if they'd seat, fine, if not, I ejected them. My memory is that I simply shot the fatties out of another revolver. I don't remember throwing out the brass, either, so dang, I guess I just don't remember
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I have no advice as to the advisability of having your chambers reamed. I've never had it done, and would probably sell the gun, first, if it became a recurring issue. Not that it's an exotic problem, just that there's a lot of nice S&Ws out there.
I use .358 laser cast bullets. When seated, the top of the cartridge is noticeably bulged from this "oversized" bullet, but I've never had a problem seating the cartridge in the chambers due to the bullet, including .38s, .357, .44mag, and .45LC.
If you've never tried any, you might give Remington brass a try. Remington case walls are the stoutest, and may be what you need to resist the battle of the bulge...
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