9mm reloading – The ExhaustNotes Blog

The 9mm Sudden Unintended Disassembly: Concluding Thoughts

By Joe Berk

This is an update on my 9mm 1911 sudden unintended disassembly saga. I will address four topics:

- - Zeroing in on the cause.
  - Rework of the ammo I had loaded on my Lee turret press.
  - My reconstituted 9mm 1911.
  - Preventing a recurrence.

Let’s get into it.

Zeroing In On The Cause

I’m down to thinking the 1911 event was due to either of two causes: A double propellant charge, or bullet setback (i.e., the bullet slid deeply into the case as the round was being chambered, thereby raising the chamber pressure).

My burst 9mm cartridge case. It was a Remington case, not that it makes any difference. Any case would likely have burst. Photo by TJ of TJ’s Custom Gunworks. Compare this to the photo of the double-charged case at the end of the video below.

A Double Charge

I did a Google search on double-charged cartridges, and what do you know, there’s actually someone out there who did the same thing I did. He caught it on video and posted it with a photo of the case. His burst cartridge case sure looks a lot like mine.

If you compare the photo at the end of the above video to the case stuck in my chamber, they are identical. I’ve convinced myself that this is the most likely of the two scenarios, but I’ll describe the other scenario (bullet setback) as well.

Bullet Setback

What has me thinking deep thoughts about the second failure mode (pushing the bullet deeper into the case during chambering) is that I think it is relatively easy to screw up while reloading and induce this failure, and from what I’ve read, 1911s are more prone to do this than are other semi-autos.

Let’s discuss screwing up the reloading process in a manner that could induce bullet setback. On my Lee Classic turret press, bullet seating and crimping occur in two separate operations (seating refers to pushing the bullet into the case; crimping refers to locking the bullet in place by crimping the cartridge case mouth). The third (of the four) dies seats (but does not crimp) the bullet; the fourth die applies a taper crimp to the bullet. Here’s the screwup: I’ve had at least a couple of instances where I took the cartridge out of the press after seating the bullet (but before crimping it). I know; you’re thinking that’s stupid, and I can’t argue with that conclusion. I don’t know why I did it (too eager to see the completed round, maybe?). I caught myself, returned the cartridge the press, and crimped it. But it’s possible I missed the crimping step on a cartridge.

I think setback is the less likely of the two failure modes discussed here. I tested the crimp by tapping on the bullet with a rubber mallet and it didn’t move. Failure to crimp or a weak crimp may have caused setback, but on properly crimped bullet, I don’t think setback will occur. Also, when I made the cartridge shown in the photo above on my RCBS Rockchucker press, it took more effort than I thought it would to seat the bullet as deeply as you see in the photo (and the case had not been crimped). I doubt that simply chambering the round would drive the bullet in that deeply (even without a crimp). If you think otherwise, please leave a comment below.

Gun Design and Bullet Setback

As mentioned above, bullet setback is more likely to occur on a 1911 than it is on other semi-auto handguns. It has to do with cartridge location in the magazine, and how it feeds into the chamber. On more modern handguns, the top round in the magazine sits higher in the gun than it does on older design guns. When the slide shoves the round forward, cartridges in more modern handguns have a straighter path into the chamber. On a 1911, the top round in the magazine sits lower in the gun. When the slide pushed it forward, the bullet impacts the ramp, it has to stay situated in the cartridge case without experiencing setback, and the cartridge has to rotate up and then into the chamber. Because of this, a 1911 is more likely to experience bullet setback than is, say, a gun like the S&W Shield.

A 9mm cartridge waiting to be chambered in a 1911. It’s a little hard to see in this photo (I did the best I could), but the bullet nose will hit the ramp head on and then slide up the ramp and into the chamber. The potential for bullet setback is a little higher here than on most other modern 9mm semi-auto handguns.

A 9mm cartridge waiting to be chambered in the S&W Shield. Notice how the round is nearly aligned with the chamber as it sits in the magazine.

That’s not to say the Smith and Wesson Shield is a better design or that it’s all sunshine and rainbows. There’s a tradeoff the engineers made on the Shield. Yep, the Shield’s higher cartridge position makes for a straighter path into the chamber. It also allows for higher capacity in a smaller gun (my little Shield holds 8 in the magazine and one in the chamber). But the higher cartridge position can induce another issue: Failure to extract and eject.

A cartridge case in the S&W Shield caught during extraction on the mouth of the case immediately below it.

During extraction, the round being extracted has to drive the magazine’s top cartridge down into the magazine as it is being extracted. it does so by using the next cartridge’s bullet as a cam surface. The rear edge of the cartridge being extracted bumps into the mag’s top cartridge, and then it has to drive it down so the case can exit the gun after firing. As it uses the bullet of the mag’s top round for that cam surface, the rear of the cartridge case rim encounters the case mouth of the mag’s top cartridge, and that can cause a failure to extract and eject. It’s happened to me. I’ve found the Shield is sensitive to ammo brand, bullet configuration, and crimp. Too much crimp, and the cartridge goes too deep into the Shield’s chamber and the firing pin won’t light the round off. Too little crimp and it jams in the manner described above. Too little crimp and it might experience bullet setback. Like most things in life, the design is a tradeoff.

Again, I don’t think bullet setback is what happened in my 9mm 1911. I’m including it here simply because it is interesting and relevant to this discussion.

Ammo Rework

One of the personally dismaying and embarrassing things about blowing up my 9mm 1911 is that it immediately threw into question the approximately 1500 rounds of 9mm and .45 ACP ammo I had reloaded on the Lee turret press.

I thought I could use weighing the rounds as a way to screen for double loads, but on both the 9mm and the .45 cartridges, the weight variation exceeds the weight of the powder charge. That means I could have a double charge and if it was in a lighter round, it would be within the variability for the loaded cartridge. So weight was not a way to screen. I know there will be keyboard commandos with advice to stick to one case manufacturer (or to segregate cases by brand), but the same variability problem exists even when cases are segregated (I’ve checked). I wish the self-styled “experts” on Facebook would slither back under their rocks (or at least refrain from commenting when they just don’t know what they are talking about, which is most of the time).

The RCBS collet bullet puller. You put your cartridge into the press shell holder, raise it into the collet (the gizmo on the right, which fits inside the gizmo on the left), tighten the crank, and lower the press ram. Voila, the bullet is pulled. Most of the time. Sometimes it doesn’t work.

An impact bullet pullerr. You put a loaded cartridge into the cap on the hammer head, whack the opposite end against a hard surface a few times, and inertia drives the bullet out of the case. It is a lot of work.

The Grip-N-Pull. It works occasionally. I tried a few cartridges and gave up on it.

I’ve disassembled and reassembled the 800 9mm rounds I loaded on the Lee turret press. I did not find a single one with a double charge. I used my buddy Greg’s RCBS collet bullet puller for this on my 9mm ammo and it worked like a champ with minimal or no bullet damage. Surprisingly, with all brands of brass, after pulling the 9mm bullets from crimped cartridges I did not have to expand the case mouths again to reseat the bullets. They slid right in. I just seated them to the right depth and crimped them again. Reusing the bullets didn’t seem to affect accuracy, either.

The RCBS collet bullet puller did not work on my .45 ACP ammo. The .45 collet couldn’t get a good enough grip on powder coated 230-grain roundnose bullets or on my 185-grain cast semi wadcutters. I tried one of those Grip-N-Pull devices and that didn’t work, either. The bullets slid right out of it. To disassemble the .45 cartridges, I had to use an impact bullet puller, and that was tough sledding. It takes forever. I don’t like impact bullet pullers, but hey, it is what it is. And what it is, well, is a lot of labor. I’m working it a little at time, at a rate of about a box per week. Three or four months and the rework will be in the rearview mirror.

That double charge sure turned out be one expensive mistake, both in terms of damage to the 1911 and the need to rework a lot of ammo. Live and learn, I guess.

The Reconstituted 1911

TJ (of TJ’s Custom Gunworks) worked his magic on my 9mm 1911. As mentioned in a previous blog, in addition to addressing the damage from the burst cartridge, he polished the barrel and ramp, refit an extractor that actually works (shame on you, Springfield Armory, for letting this one get out of the factory with an extractor that didn’t even contact the cartridge case), he recontoured the slide release and the slide release pin (shame on you again, Springfield Armory, for a slide release that was extremely difficult to install), he fit a one-piece guide rod (which is what I asked him to do), and he did one of his magnificent trigger jobs (this 1911 has a “breaking glass” 2 1/2 pound trigger now, with zero creep and no discernible takeup). This 1911 is a pure joy to shoot. I loved it before and I love it even more now. That target at the top of this blog? It’s a full box of my reloaded 9mm ammo (50 rounds) fired without resting the gun on anything. No failures to feed, no failures to eject, no misfires, and every bullet hit in the 10 ring.

50 rounds shooting offhand with the 9mm Springfield Armory 1911. Custom work by TJ’s Custom Gunworks.

Preventing a Recurrence

Wow. Where to begin.

I am implementing a number of changes in my reloading to prevent this from occurring again:

- - I’m slowing down and paying more attention. Duh. I’m no longer complacent. Duh again.
  - I’m installing better lighting on my press.
  - I’m standing up so I can see into the cartridge case.
  - I’m switching to a bulkier powder so that a double charge, if it ever occurs again, will spill over the case mouth and make a big, impossible-to-ignore mess.

I don’t mind sharing with you that when this first occurred, my thought was to abandon the Lee Classic turret press and return to loading on my single stage RCBS Rockchucker press. Double charging a case using a single stage press is (in my opinion) a much less likely thing to happen, and in 50 years of reloading on the Rockchucker, I’ve never had it happen.

When you load on a single stage press, it’s easier to view all of the charged cartridge cases. If any have been double charged, they will stand out.

I have a friend who works for Colt in their customer service department, and he tells me that when he sees a blown up gun sent in, there’s usually a progressive or a turret press somewhere in the story. But good buddy Paul told me to think about it a while longer and I did. I’m back to using the Lee turret press, but I’m a little older and a lot wiser now. The older part wasn’t really necessary, but the wiser part is and hopefully, readers can benefit from my screwup.

Slowing Down and Paying Attention

You know, when I worked in the munitions industry I participated in two fatality investigations where inadvertent detonations were involved. Multiple human errors caused those inadvertent detonations, and one of the key human errors was complacency. That’s what I had become using the Lee Classic turret press: Complacent. I’d been reloading for so long I became entranced with the turret press’s speed, and I started reveling in the thousands of rounds I was cranking out (and it was, literally, thousands of rounds). I always knew that double charges or skipped steps (like crimping) were really, really bad, but I just never thought I’d be the guy making either mistake. I wasn’t taking the time I needed to and I became complacent. That’s changed. I’ve slowed the pace, and you can bet I’m looking into every case immediately before I place a bullet on top to make sure I haven’t double charged it. You can also bet that I’m making sure I hit the crimping step on every round. I’ve actually posted a sign on my reloading bench with the best advice I’ve ever given myself: Slow down.

Better Lighting

Good buddy Duane (who is both smarter and better looking than me) also reloads with the Lee Classic turret press. Duane mounted a light above his press to allow better visibility into the charged case. I’m going to do the same.

Standing Up

I used to sit at the reloading station. My bench, though, is higher than a standard work table (it’s how I had it built 50+ years ago). When I’m seated, it’s not as easy to see into the case. I reload standing up now, and that allows seeing directy into the case.

Bulkier Propellant

My last change concerns the propellant. One of the things I investigated shortly after my 9mm hand grenade episode was if it was possible to get a double charge into a 9mm case. With the load I was using (5.4 grains of Accurate No. 5), the answer was yeah, you could. It even had a little room left over. My thinking at the time was that I needed to go to a propellant that would overflow the case if I double charged it. In the past, I’ve found 4.8 to 5.0 grains of Unique with the 125 grain bullet is a marvelous 9mm load. Doubling that (i.e., 9.6 grains of Unique will overflow a 9mm case) and if that happens when loading, that’s a good visual indicator that something’s wrong. So, from here on out when using the Lee turret press, my load will be 4.8 grains of Unique. That only works for 9mm, though. Other cartridges (the .45 ACP, for example) will handily swallow a double charge. There, it’s back to paying serious attention (which we need to do on everything when we reload; it’s just using a propellant that will spill over with a double charge adds an additional indicator if things aren’t done correctly).

A double charge in the case on the left. My load was 5.4 grains of Accurate No. 5. I loaded both cases with this charge, and then took the propellant from the case on the right and poured it into the case on the left. A 9mm can easily swallow a double charge of Accurate No. 5.

A single (correct) charge: 5.0 grains of Unique in a 9mm case.

The most Unique I could load into a 9mm case was 7.9 grains. A double charge would spill over the top of the case and be immediately noticeable (at least in 9mm; the .45 ACP case will take a double charge of Unique without a spillover).

Incidentally, when this happened, I wrote to Lee and asked them if they offered any accessories to prevent a double charge (my Star reloader has a mechanical feature that prevents this from occurring). The answer was no, but Lee advised using a propellant that, well, read the above again and you’ll know. I checked the literature that came with the Lee Classic turret press kit, and sure enough, Lee has a recommendation in there to do exactly what I describe here.

Hornady’s Powder Cop

When I posted earlier blogs on Facebook, a few people mentioned a reloading cop. In 50 years of reloading, I’d never heard of such a thing, but I found it on Amazon. Hornady’s Powder Cop die is a die with a pushrod indicator. You add it to a vacant station on the reloading turret after the propellant charging station and when the charged round goes into it, if the case is double charged the rod will go higher than it normally does.

I don’t think the Powder Cop is the answer for several reasons. The Lee Classic turret press doesn’t have an empty station in its turret (all four stations are taken by the Lee 4-die set), you would have to notice that the pushrod indicator rose marginally higher than it was supposed to, and I believe that if a double charge was present, the pushrod might just push into the powder and not rise enough to indicate the double-charge condition. The Powder Cop might be right for some people, but my equipment can’t use it and I don’t think it’s an effective check. If you missed the double charge, you would probably miss the rod extending upward a bit further, too.

The RCBS Lockout Die

RCBS offers their lockout die which is, in my opinion, the best option for preventing a double charge on a reloading press, if the press that has an open station. If the case has an overcharge or an undercharge (or no charge), the lockout die locks the press, which positively lets you know that something isn’t right. It’s a clever mechanical device that detects either and overcharge or an undercharge and then stops the process.

Unlike Hornady’s powder cop die, the RCBS lockout die isn’t just a rod moving up and down. The lockout die stops the show and forces you to check the cartridge that has locked up press movement. I think it’s a much better approach. The problem, though, is that you need that extra station on either a turret or a progressive press, and I don’t have that on the Lee Classic turret press (so for me it’s a nonstarter). What it says to me is that if I were to buy a new press, I would want one that has an extra station. I think the lockout die is a stellar idea; I just don’t have the real estate for it on my press.

The Bottom Line

I’m convinced that I had a double charge in the round that burst in my 1911. I’m also convinced that it’s on my to prevent it from happening again. As explained above, here’s what I’m doing:

- - I’m slowing down and paying attention to what I do. There is no place for complacency in the reloading world.
  - I will continue to use my Lee Classic turret press, but I’m installing better lighting and standing up so I can see into the cartridge case.
  - I’m switching to a bulkier powder so that a double charge, if it ever occurs again, will spill over the case mouth and make a big, impossible-to-ignore mess.

So there you have it. If you have any thoughts on any of the above, I’d sure like to hear them.

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Shield Savvy

By Joe Berk

I promised an update on my Smith and Wesson 9mm Shield, and this is it. I’ve put 2,500+ rounds through the Shield (all reloads with different bullets and powders). Until I recently took my Shield to good buddy TJ, I was growing increasingly dissatisfied with the pistol’s frequent failures to extract, and I wasn’t alone. If you Google “failure to extract” and “Smith and Wesson Shield” you’ll find a lot of people are having this issue. My problem is in the rearview mirror, though, and my Shield is 100% reliable now. That’s because of TJ. I’ll get to that in a minute.

That target above? It’s 50 rounds at 30 feet through my Shield, shooting offhand. If you’re a reloader, here are the load specifics:

- - Jim Gardner 125 grain powder coated roundnose bullets (Jim sized these to 0.356 inch, which is his standard bullet).
  - Cartridge overall length 1.145 inches.
  - 5.4 grains of Accurate No. 5 propellant.
  - Lee factory taper crimp (light crimp; see below).
  - Ammo loaded on Lee Classic 4-Turret press.
  - Mixed brass.

Ordinarily, I tailor a load to the handgun, and I thought I would be able to do that relatively easily with the Shield. I found that not to be the case. The Shield seemed accurate enough with nearly every load I tried, but nearly all had reliability issues. On the low end, the lighter loads didn’t have enough energy to cycle the action (a common enough problem on compact semi-autos). Light, mid range, and hot loads all gave the Shield extraction issues. The Shield experienced a failure to extract about every other magazine. It was very frustrating. I scoured the Internet forums for this issue and the opinions were all over the map. Here’s a smattering of the drivel I found:

- - Don’t use Winchester ammo because the rims are smaller (I measured them; that was baloney).
  - Don’t use cast bullets because they hang up (I knew that was baloney).
  - Don’t shoot aluminum ammo (which I never do, anyway).
  - Don’t shoot 115-grain bullets.
  - Don’t shoot 125-grain bullets.
  - Don’t shoot 147-grain bullets.
  - Clean your gun after every round (seriously?).
  - Don’t limp wrist your gun (again, seriously?).
  - Don’t do this, don’t do that, don’t do this other thing…
  - Do this, do that, do this other thing…

It was all written by people who apparently love the sound of their keyboards clacking. None of it was useful information. I felt stupid for wasting my time reading it.

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What I found was that the extraction problem occurred more with powder coated bullets than either plated or jacketed bullets. Other than that, there wasn’t a lot of correlation between any of the load variables I could play with and the gun’s failure to extract propensity. Then, during one range visit when I had a failure to extract, I fell back on my failure analysis background. I put the loaded gun down on the bench (being careful to keep it pointed downrange) and took a photo with my iPhone.

A cartridge case caught during extraction on the mouth of the case immediately below it.

Wow. How about that? It was apparent that the case being extracted was hanging up on the case mouth of the round still in the magazine, and it was a strong enough obstacle to pull the extractor off the rim. This brought up a lot of questions in my mind centered on the crimp and the bullet. The Gardner bullets have a slight ramped step just north of the crimp. And when I crimp a bullet for a semi-auto, I put a slight taper crimp on it with the Lee taper crimp die. I want enough of a crimp to remove the case mouth flare (part of the reloading process to assure the bullet will enter the case mouth without shaving lead or copper), and enough to assure the cartridge will chamber easily. Maybe I didn’t have enough crimp, I thought, and that was causing the case being extracted to hang up.

One of my reloaded 9mm rounds with a taper crimp and a Gardner powder-coated bullet.

I examined my ammo and I thought it looked good (actually, I thought it looked great; like most reloaders, I enjoy looking at my finished ammo). But, to make sure, I loaded another box with as much taper crimp as I could get out of the Lee die. Lee is right when they say their taper crimp die makes it impossible to deform a case: I put a very pronounced crimp on all the cartridges in the next box of ammo. But that wasn’t the answer, and it created a new problem. With a semi-auto like the 9mm or the .45 Auto, the cartridge headspaces on the case mouth. When I used a more pronounced crimp, I started getting misfires. The rounds were going too far into the chamber, and the firing pin wasn’t igniting the primers reliably. Nope, more crimp wasn’t the answer.

At this point, I was getting a little frustrated. All these problems aside, I wanted to like my Shield. I wanted to use it as my concealed carry weapon, so I needed the thing to be reliable. Faced with this issue, I knew it was time for what works every time: A visit to TJ’s Custom Gunworks.

TJ examined the Shield. He observed that the magazine positions the first cartridge in the magazine unusually high in the gun, and that was probably aggravating the failures to extract. But there’s not really anything you can do about that. It’s the gun’s design. It is what it is.

The Shield’s magazine sits relatively high.

A loaded round waiting to chamber when the Shield’s slide returns to battery.

TJ then took a look at the extractor. It was pretty dirty with combustion residue, but he felt it should work. TJ, honest as always, told me he could polish the ramp and the chamber (they come from the factory pretty rough), but he didn’t know if that would fix the failures to extract. I asked TJ to proceed.

A photo from TJ showing how dirty my extractor was. Even though it was funky (shame on me), TJ felt it would not have caused the extractor to slip off the case rim.

Here are a couple of photos of the chamber and the ramp as they come from the Smith and Wesson factory. The Shield always fed and chambered reliably; it was only the extraction that was an issue. TJ explained that if the chamber is rough, it can hang on to the fired case as it is being extracted. I’ve experienced that on other guns. The Shield’s chamber and its ramp looked about like I’d expect them to look on a mass-produced pistol, which is to say not very good. I asked TJ to work his magic on both the ramp and the chamber.

The Shield’s feed ramp and chamber as delivered from the factory. Rough, but not ready.

Another view of the factory Shield feed ramp. It looks like it might have been cut by hand with a dull chisel.

TJ did his usual excellent job, and here’s what things look like now.

What a good ramp looks like. Slick. Smooth. Shiny.

TJ told me he also put a slight undercut on the extractor to allow it to get a better grasp on the case rim.

The Shield’s extractor, as seen from the bottom. This is the piece that pulls the fired case out of the chamber. TJ undercut the area indicated by the arrow to give the extractor a better grip on the case.

I picked up my Shield a few days later and went to the range that afternoon. The Shield is now what it is supposed to be. You saw the target at the top of this blog. I fired 50 rounds without a single failure to extract and eject. The gun just feels a lot smoother and slicker now. My Gardner bullet and Accurate No. 5 load is perfect. And the recut extractor drops the cartridges in one nice small pile on the floor behind me. Wow. I’m impressed. Then, just to make sure (and because I was having so much fun) I fired another box of 50 rounds (again, with ammo loaded on the Lee Classic Turret press using the load at the top of this page).

Another target, another 50 rounds. Reliable as death and taxes, and accurate. Now, the Shield is as it should have been from the factory (thanks to TJ).

The Lee Classic Turret press does a magnificent job, and now, so does my Smith and Wesson Shield. It’s the way the pistol should have come from the factory.

It’s bothersome that most of my recent gun purchases have required additional work to get them to perform the way they should. In my former life as an aerospace manufacturing guy, I used to manage organizations with machine shops. I know it would cost a little more for the gun companies to do the kind of things TJ did to my Shield (and several other guns, for that matter). I wish the gun companies would do that; they ought to just hire TJ as a consultant (he knows what they need to do). The bottom line here? If you have a Smith and Wesson Shield and you want it to be what it is supposed to be, get in touch with TJ.

There are a lot of things I like about the Shield. Accuracy and illuminated sights are at the top of the list. You can get a feel for its accuracy from the targets shown here. None of this was bench rested; it was all shooting offhand on an indoor range with banging and clanging and brass flying all around me.

I found that after firing a a box of ammo, gunshot residue tends to occlude the sides, front, and rear of the front sight, and that causes the red to glow a lot less. But that’s a minor point. The Shield’s high visibility sights are great.

Holstered, the S&W Shield is about the same size as the Rock Island Compact 1911.

Another Shield-to-Compact-1911 comparison: The holstered Shield on top of the holstered 1911. Length and height are about the same.

The Shield is narrower than the 1911, and much lighter. It should be easier to carry concealed.

I bought a Bianchi leather holster for the Shield. It’s similar to the Bianchi I use with my Compact 1911. When I put the Shield in its holster I was surprised: It’s really not any smaller than my Compact 1911. It’s a bit narrower, but by the time both guns are holstered, the overall width is about the same. Where the Shield has a clear advantage, though, is weight. And even though the Shield with its polymer frame is much lighter than the Compact 1911, the recoil is quite a bit less than the .45. Now that the Shield has been made more reliable by TJ, it will make a good concealed carry gun. Incidentally, TJ worked his magic on my 1911, too. It’s one of the most reliable handguns I’ve ever owned.