For those that load 38 special

Crown, cylinder throats, timing and primers would seem to make the most difference. Same lot of cases, uniformed primer holes and depth, powder positioning, adding the next size longer bbl to your Dan Wesson might help.
Really the only reason to keep the same load components is if they work for you or you have a lot of them. If you are overstocked with inaccurate components you can't change much.
 
You said you are only crimping enough to remove the bell. Try a medium or medium heavy crimp to insure a proper burn of the powder and see if that improves the accuracy.
 
Used the caliper checked the chambers after cleaning them .355 to .356

I don't think that's a particularly accurate way of measuring, as calipers aren't that accurate but also because the flat measuring surface will not properly contact the round chamber surface.

Does the bullet you are using drop through?
 
Wadcutters

For target loads a 146 wadcutter usual rules supreme.It is "the cats meow". Just 1 factor in an accurate load. Low recoil helps also
 

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Take one lot of cases for that particular pistol or revolver. size then trim, clean primer pockets tumble them. Keep these cases together just for that particular firearm. Keep a small writing tablet (stenographers tablet works fine) record how many times fired,what loading, accuracy,take,time,weather. Any sight changes from the last time. In time you will have aquired some valuable ballistic information. Frank
 
I don't think that's a particularly accurate way of measuring, as calipers aren't that accurate but also because the flat measuring surface will not properly contact the round chamber surface.

Does the bullet you are using drop through?

Nope, I cant push it through either, I have to spend some time hammering it through.

Edit: Pushed several bullets through and measured their diameter, most chambers size it down to .357
and two size it down to .3575
 
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Nope, I cant push it through either, I have to spend some time hammering it through.

Edit: Pushed several bullets through and measured their diameter, most chambers size it down to .357
and two size it down to .3575

I'm not an expert to know if that is on the narrow side or not. I believe it's a plus that the bullets are larger than the throats. Ideally you'd also know the barrel diameter, and hope the throats are slightly larger. However, a thought also occurs. Do you use a Lee factory crimp die? Many people accuse it of swaging down lead bullets.
 
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With a group size that large and flattened primers something is definitely off.

I'd just point out that he is using Federal primers. They are always flat for me, even in 38 and 44 special loads. I don't think that means much.
 
One thing that could be done would be to use the best quality measuring tools. The vernier calipers I see on my friends reloading benches are usually junk. Reloaders could bring things a couple notches by using quality, barrel micrometers instead. Now, it's true that I'm an old time toolmaker and set in my ways, but I'll never use a micrometer with a digital readout.
It's just not that hard to read a micrometer and a traditional barrel mic can be handed down for generations. My favorite brand is Starrett. A 1" model 436 would be good for barrel slug measuring to +- .0001. Won't get that with a cheapo Chinese caliper. There are anvil types that can be set up to measure case wall thickness and I.D. types to measure things like cylinder throats. So if you want better measurements, ditch the calipers and move up to micrometers.
 
What is the actual measured diameter of the coated Bayou bullets? You indicated that your best caliper measurement of the throats was .355-356, yet the bullets after being hammered through are .357-3575. Probably just the difference between an OD often being easier the measure than ID.

If you want to use lead bullets, the throats may need to be made uniform at .3575, which is the common reamer size. I have had Smiths and Rugers reamed, so your situation is not unusual. Using lead bullets is not a slam dunk. Everything has to be just right.

p.s. it seems that most guns are a work in progress.
 
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Just a quick update, pushed out my OAL to 1.525 and back off the crimp to just enough to remove the belling so it no longer leaves an impression on the bullet. Made a big difference back to 4" off hand groups.
 

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