After hand cycling a magazine of dummy rounds thru the test gun several times I settled on .970" as a functional OAL. One thing that bothered me is how far the bullet seats into the small case, reducing volume and raising pressure. It requires .096" more case space than a similar 90gr XTP. This would be like seating the 90 gr to an OAL of .874" which is way shorter than any standard and insane to consider in the first place. Seems like every time I find an answer to one question, all I come up with is more questions.
I spent some morning coffee measuring various case dimension of both OEM loaded and (10 case) groups of various brands of fired cases. The different brands varied quite a bit from one another in their extremes. Maybe I've been handling 44's too much lately but the 380 impressed me with just how small it is for the performance derived. I "discovered" two things that have already been mentioned by the experienced posters above.... 1. there isn't much case capacity so pressure is gonna be tricky to handle safely and 2. the .380 brass is thinner than most. The .380 cases I measured with a tube micrometer are typically .008" at the mouth while a 45acp is usually .011". I suppose I could use nickle cases which are .009", but that would reduce the internal volume and drive pressures more. A quick check shows SAAMI max is actually 500psi less for the 45 and 38 SPL +P than it is for the .380 ! I'm not so sure I want to play in that sandbox.
I decide to find more info on powders, pressure and the 380 in order to consider which powder to work with. Since most of the old manual data gives pressure in CUP I was looking for info on a way to correlate CUP and PSI. I did find one study by Denton Bramwell that seemed to support a correlation formula that works for rifles but the author cautioned that it didn't hold true for pistol cartridges. Also the math involved in creating my own regression plot is more than I want to get into at the moment. At some time in the future, I might purchase the Quickload program, but I doubt it, as retirement affords a lot of things but extra cash is not one of them.
I also wanted to see if there were any powder pressure curve charts available for study. I wasn't able to find much info on the subject (ignoring most internet forum chatter as opinion) but I did turn up some interesting articles discussing pressure and powders in general. One that some here might find interesting, is a 2011 Shooting Times article by Allan Jones. He relates his experiences testing load pressures and converting from CUP to PSI during the writing of the Speer 12th edition manual. For those interested, it can be found here...
CUP, psi & Reloading Data
Some of the info in that article and a couple others, plus considerations posted in this thread, have caused me to reconsider my original idea. I believe I now understand one reason those heavy bullet .380 loads were dropped from the manuals...They are a little too close to the edge and unpredictable reloading variables are just too much of a risk (for my comfort) without a big budget test lab to control & verify results. I might still try a couple of 115gr with the old starting loads, but I'm not so sure there is anything to gain except bragging rights. I might just spend the emergency room co-pay money and buy some Cor-Bon or Buffalo Bore fodder to play with instead....
Thanks for all your input, I appreciate it and I hope this thread hasn't been a waste of time, I know it hasn't been for me. If I do go ahead with this, I'll report back my results.
Thanks
Al