Cast Bullets Bonding to Case Necks - Findings

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Wilderness posted this 15 April 2026

Further to my earlier post on lubed cast bullets bonding to case necks, I have continued testing with the following results:

  • An unlubricated lead bullet seated in a clean case neck seats easily, and a short time later can be seated further without any change to resistance. Then, after as little as one day undisturbed, the bullet seriously resists deeper seating, and when it moves it does so with a pronounced crack. This is what I call “bonding”.
  • A cast bullet lubricated in a Lube Sizer and then sized further in Lee dies will emerge with lube in the grooves, but with bands wiped clean. This bullet when seated behaves similarly to an unlubed bullet. This is the scenario that first caught my attention. My example was #U321297HP lubed in .323” die then sized in Lee .314” die, then again in Lee .311” die. Bonding occurred with BAC, 2500+, LBT, LSM and to a lesser extent LOM. BHN 16.
  • Cast bullet #321297HP lubed and sized as per #2, then tumble lubed with LLA . At day 18 there was no additional resistance – ongoing, will update.
  • Cast bullets #311008 sized and lubed normally with 2500+ in a .310” Lube Sizer die gave mixed results after a few weeks. Of five cartridges tested, one cracked, two made a bit of a sound, and two went smoothly. Bullets were seated to cover just one band. BHN 14.
  • Cast bullets #311008 sized in the Lee .311” die, then lubed with 2500+ in Lube Sizer with .312” die, appear to have avoided bonding (normal resistance still to day 40). Bullets seated to cover one band.
  • Cast bullets #311008, sized dry in Lee die (.311” die), then treated with LLA, and loaded to cover two bands, slightly increased resistance but no bonding to day 24. This does not preclude the possibility of some sort of adhesion further down the track from LLA, for which there is some suspicion.

In all instances, necks were expanded with Lyman 31M die.

Bonding appears to follow from sizing that wipes the bands clean, as in Lee sizing after lubing. The seated bullets then have direct lube-free contact between bullet metal and case neck. Type of lube may influence whether traces of lube remain on the bullet bands after lubing and sizing. Normally sized and lubed bullets remain as a maybe.

Bonding may be no bad thing so long as it is uniform. Indeed, bonding may be sought for automatic pistol cartridges or tube magazine rifle ammo, or for powders that benefit from extra resistance at start.

Where ammo is to be used over time and bonding is expected, testing for group, velocity, zero etc can be delayed after loading to ensure bonding state at test mirrors likely state at time of use. I leave mine at least a week before testing.

The ballistic effects of bonding were not pursued beyond the initial observations (previous post).

You are only as good as your library.

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Ross Smith posted this 16 April 2026

W.    I just found what you have been posting about.In our e-mail exchanges I wrote that my fully lubed bullets did not bond to the case. Today I pulled the bullets on some '06 cases where just the GC gap is lubed . They were stuck. Clean bullet, clean brass, some bonding occured.  Ross

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Lucky1 posted this 16 April 2026

Next step after finding some do indeed bond. Does it affect the group size? Do the SDs get bigger if they bond and there is more variability than unbounded?

Scott Ingle

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Wilderness posted this 16 April 2026

Ross - thank you for the confirmation. Just to raise some confusion, is the possible effect of bonding confounding the evaluation of minimal lubing?

Scott - indeed. I have a little way to go still defining the conditions of bonding. I would be delighted if one of the Members were to take the next step and run some properly structured tests of bonding versus non-bonding.

Suggested protocol might be to start with a combination known to bond. Load some ammo with normally seated bullets, enough for a group (or groups). At the same time, load some with bullets not fully seated, enough for a group plus some spares for bond checking. Periodically (perhaps weekly) check for bonding by reseating one of the spares. Once bonding is confirmed, prepare the "non-bonded" group by reseating, preferably immediately before shooting. The reseating will break the bond and put the ammo back to "newly loaded" status. Bond may begin to reestablish within a day, hence the requirement to reseat as close as possible to shooting time.

I suspect that we might find that bonding affects some loads more than others, and that variability may be a bigger issue than bonding itself.

My own observations so far are just twofold:

  • .30-30 loads with BM2/Benchmark powder at high teens velocity - week old versus morning-after ammunition picked up 41 fps over a week. Group was already bad, with pronounced stringing due to velocity spread, so no useful info there. I suspect that BM2 requires more pressure to burn properly and hence was benefiting from the extra resistance. Bullets were 175 gns lubed (BAC) and gas checked then sized (twice) in Lee dies with no further lube.
  • .30-30 subsonic loads with 160 gn bullet lubed (BAC) then sized in Lee dies, 5.5 gns Unique. "Bonded" ammo was at least a couple of months old. "Non bonded" was the same ammo reseated a few thou deeper (the night before), so not quite apples and apples. Shooting was with iron sights at 50 meters, five shot groups only. [Incidentally, same load, same age, lubed with beeswax and synthetic two-stroke oil, had not bonded - not tested unfortunately.]

 

               Velocity     SD    Group     POI

 

Bonded     1022       16      1.91”   -1.55”

 

Cracked     1000        7      1.19”    -2.16”

 

 

 

You are only as good as your library.

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Lucky1 posted this 17 April 2026

Thanks. I was wondering if loading enough 06 for the next 3 matches was a mistake or not. Time will tell.

Scott Ingle

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Ross Smith posted this 17 April 2026

W.    When I was looking for a standard-go to-Load for all my '06s is when I found that the hoch 310-185 bullet with a minimal lubing was the most accurate general load across the board. Not my best accuracy load for my custom '06. Infact I would not have found the bonding (electrolisis) issue had I not have two failure to ignite rounds. So I pulled everything apart to locate the problem.(Old military primers)threw the remaining ones away.That's when I noticed the adhesion. When I was testing for good general accuracy it was the amount of lube that I was testing. So I might not be able to answer your question. The 30+ plus shots I took yesterday contained no suprises.

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Ross Smith posted this 17 April 2026

I'm bad about not tumbling my cases until they really need it. Maybe that's why I haven't noticed adhesion because I pull a lot of rounds apart when I find that load does't do what I wanted. Maybe the answer is to not clean your brass.

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Millelacs posted this 03 May 2026

     Thanks. I was wondering if loading enough 06 for the next 3 matches was a mistake or not. Time will tell.
Could a solution be to load three matches of ammo "Long" COAL, and then "shorten" them to the proper length the night before a match?

 

 

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