Handloading the .38 S&W

I do recall either Lyman or Lee did size down to .358 and maybe the decapping/sizing die was actually a .38 Special die. If you are using cut down 38 Special cases, loading the .358 bullets might work, but dimensions of the inside of a 38 S&W case measure .361, so ? ? I assume that many people have never shot the larger bullets in their 38 S&W revolvers, but will still state with experience, accuracy will suffer without the right size bullets.
 
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I had to go back and look at my die set. Lee 38 S&W set has a decapping/sizing die that is stamped 38 AUTO meaning it is a .356" die. I forgot that I had a resizing tool made by a friend that sizes the cases to .361 in a separate step. I had it made for a 38-44 Target case made from 357 Maximum brass that also worked to resize my 38 S&W cases.

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You have touched on the issue i am having with reloading my 38 S&W. I have the Lee dies and as you noted it uses a 38 auto sizing die. Since I had intended to load 357/358 158 gr lead bullets I thought this a good idea. I then used the standard Lee expander die . I was using some nickle plated Winchester brass and all seemed to go together pretty well. When I switched to the Remington brass (unplated) the bullets just slid in to the case. I then tried a Lee 9mm expander with the same results. I put the calipers to the brass and discovered that the Rem brand brass is thinner .
 
You have touched on the issue i am having with reloading my 38 S&W. I have the Lee dies and as you noted it uses a 38 auto sizing die. Since I had intended to load 357/358 158 gr lead bullets I thought this a good idea. I then used the standard Lee expander die . I was using some nickle plated Winchester brass and all seemed to go together pretty well. When I switched to the Remington brass (unplated) the bullets just slid in to the case. I then tried a Lee 9mm expander with the same results. I put the calipers to the brass and discovered that the Rem brand brass is thinner .

I have always resized .38 S&W using, first, a Lyman steel .38 Super die, and later, a Lee carbide .38 Super die. Mostly with 125 or 158 grain cast .38 Special bullets. Have even used cast 9mm bullets sometimes. Never experienced any of the difficulties as described with any brand of brass. I do use 9mm expanding and seating dies with the .38 Super carbide sizing die.
 
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The British were always about their "Manstopper" military ammunition and the 38 caliber was no exception. They used .361" 200g lead bullets for their 38 British Service Revolver during WWII. Bullets are available at Matt's Bullets.

I have no BSRs so have no reloading data, but there are some discussions out there on reloading this cartridge if you research online. Examples are below, but more investigations are in order before reloading for them. Be careful since much of it involves using .357" bullets for 38 S&Ws and not the .361" that the 38 S&W needs for accuracy.

"3.0 grains of Unique and 3.3 grains of Herco in 38 S&W loads for the Webley-Enfield and S&W M&P revolvers and the 202 grain lead bullet run about 650-675 FPS.

200g- .361” w/2 grs. of Bullseye, 2.8 of W231 or 3.5 of Unique gives 630 fps in a 4" revolver."


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I use 2.5 grains of W231 behind a Matt's 200 grain RN in my Enfield. Very accurate.
 
I have always resized .38 S&W using, first, a Lyman steel .38 Super die, and later, a Lee carbide .38 Super die. Mostly with 125 or 158 grain cast .38 Special bullets. Have even used cast 9mm bullets sometimes. Never experienced any of the difficulties as described with any brand of brass. I do use 9mm expanding and seating dies with the .38 Super carbide sizing die.

That’s what is so weird. I can’t put my finger on what the problem is unless there js an out of spec die somewhere. The expander from the Lee 38 S&W dies mics out at .357. The expander from the Lee 9mm dies shows .355. Something is not right. Do you taper crimp your loads?
 
So I got out my S&W BSR and I determined to discover the actual fact of its bore diameter. First I measured the cylinder throats. They measured .361. So I then slugged the barrel and guess what? As close as I am able to determine the groove diameter is .360 or there abouts. I consider my revolver to be a typical example of the breed and my measurement devices , while not fancy, can tell .357 from .360.
Looks like I am using .361 bullets and the standard Lee dies.
 
When I started out loading 38 S&W (with black powder) I planned to use a 38 Super sizer, Dillon drop-through expander, and 380 ACP seater (I’m partial to taper crimp). But a friend turned me on to a guy selling new RCBS 38 S&W Cowboy sizing dies on eBay for only ten bucks! I couldn’t resist that deal….
 
Perhaps an interesting side note regarding the S&W 38 case.

Sized with a 38 super die, you can load a 9mm rimmed cartridge for your 9mm revolver.
Works well with my 940.

Why, 9mm factory is cheap and moon clips readily available?

In part, because you can. Also allows you to load light target loads that won’t cycle an automatic or use unique bullet & load combinations not found in the common 9mm loadings.
 
New to the Forum, shooting a 90 YO Regulation Police. Found new Starline brass at one of the mail order places. Shooting 1.5" groups at 50' with a dab of Bullseye and Hornady 158 lead RN, but impact is about 2.5" high. Thinking I'll try the Hornady 140 lead Cowboy, hoping the POI is closer to the aim point I'm quivering over. Thoughts?
 
When I started out loading 38 S&W (with black powder) I planned to use a 38 Super sizer, Dillon drop-through expander, and 380 ACP seater (I’m partial to taper crimp). But a friend turned me on to a guy selling new RCBS 38 S&W Cowboy sizing dies on eBay for only ten bucks! I couldn’t resist that deal….

What were your results? What size bullet did you use?
 
New to the Forum, shooting a 90 YO Regulation Police. Found new Starline brass at one of the mail order places. Shooting 1.5" groups at 50' with a dab of Bullseye and Hornady 158 lead RN, but impact is about 2.5" high. Thinking I'll try the Hornady 140 lead Cowboy, hoping the POI is closer to the aim point I'm quivering over. Thoughts?

Welcome to the forum. I've experienced the same thing with a 1920's Regulation Police and a Colt Police Positive. At 50' I got POI=POA with 125 grain bullets. You can, of course, use a 6 o'clock hold to hit the 10 ring. Go ahead and try the Hornady 140 grain bullets. I've been reloading .38 S&W for 30 years and predict it will get you about half way to where you want to be.
 
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