38 S&W load devopment Pt. 1

All I've ever seen in 358156 have probably been a little small in diameter for what you're wanting. It might be better, and less costly, to look at the Lee 365-95-1R, which is a Makarov bullet, even if it is just half the weight you're looking for.
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That 358156 is also going to use a gas check, which increases cost and may not even grab the rifling.

Another option would be to use a Lee in .357" and lap it to what size you need. If you mess it up, it didn't cost much and you can go another direction. Aluminum is a lot easier to work than harder metals, but a pitted iron mold could maybe clean up to the size you want.
 
"Beagle" your mold, if necessary

Mike,

Let me add an option to what Paul has just said. If you need to increase cast bullet diameter by a few thousandths of an inch, simply "beagle" the mold. Check out Cast Boolits website for tons of info on the subject, but here's the gist: cut tiny strips of aluminum foil and place them between and below the cavities in your mold. This will increase diameter and the very slight out-of-roundness is not a problem. Play with it a little, and occasionally you'll have to fiddle with getting a piece of foil back in place, but it works. Simple, fast, effective.

As for bullet weights, I suggest you consider something in the 180-200g range, which is these British service revolvers were designed for. Lyman's 358430 is widely used in this application, as it has the right weight and a blunt, round nose similar to the original .38/200. Generally speaking, lighter bullets will shoot lower. In my modern S&W Mods. 32-1 and 33-1, which were regulated for 145-46g bullets, I find that 158's still shoot very close to the sights, and that 200's are noticeably higher. I've never tried light bullets, as I'm generally a fan of the "heavy/slow" approach. I find they have less blast & flash, plus they penetrate very nicely. Felt recoil is more of a shove than a snap. I'm shooting my new-to-me Enfield and my newly-returned S&W Victory for the first time later today or tomorrow. Wish me luck! :-)
 
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Use some aluminum foil tape for A/C joints that has glue on one side to beagle. It used to be available from Harbor Freight in a much larger roll than you'll need to use to beagle, but it has lots of other uses. I sent some to Chunkum (RIP) for that purpose and it worked to perfection.
 
Thanks, Paul, for providing the crucial part that I was forgetting--the adhesive-backed tape! Brain glitched on that, and I was just remembering how I had to fiddle around with the stuff after the adhesive gave up the ghost.

And yes, this kind of tape is available at your hardware store.

Thanks to all, and happy casting!
 
The Lyman 45th Edition Reloading Handbook lists some very heavy loads for the .38S&W. None over 158gr in weight. I am very surprised by the Unique loads for the 150gr 358430.
 
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