reloading mistake – The ExhaustNotes Blog

By Joe Berk

A few days ago I blew up my 9mm Springfield Armory 1911. It was hellaciously frightening. I wrote a blog about it and I’ll provide a link at the end of this post. My initial conclusion was that I had committed the cardinal reloading sin: I double charged a case. Instead of the intended 5.4 grains of Accurate No. 5 propellant, I cycled the round twice at the charging station and I inadvertently loaded 10.8 grains. I know what you are thinking and that’s okay. If I read about somebody doing this, I’d think they were a dumbass, too. I’ll get back to that later.

5.4 grains of Accurate No. 5 behind a 125-grain powder coated bullet is good. 10,8 grains is not.

Thinking about the double charge issue more, several additional thoughts emerged. Were there other possibilities?

One other possibility is that instead of the failure being due to a double charge, it might have been a squib charge (which would lodge a bullet in the bore) followed by another round. This was dismissed for several reasons:

- - I knew it wasn’t preceded by a squib charge because the prior round felt normal.
  - If it was a squib charge, the following round probably would not have chambered. Squib charges resulting from no powder and pressure being provided by the primer only (in a handgun) tend to push the bullet into the barrel a very short distance (the bullet doesn’t go into the barrel far enough to allow another round to chamber).
  - The were 5 holes on the target, which is the number of rounds I had fired.
  - The barrel was not bulged (TJ inspected it and pronounced it good).

Count them: 5 holes on the target. The fifth hole is the one at the bottom. This bullet was tumbling due to its low velocity. When the case blew out, the pressure vented elsewhere.

A friend asked if I could have seated two bullets in the case. I set bullets (one on top of the other) next to a cartridge case. I think you can see that seating two bullet in the case is not possible. The bottom bullet would set higher in the case than you see in the photo below (the web near the case base and the thickness of the case “floor” would cause it to seat much higher in the case). I would not have been able to seat the second bullet even if there was no powder in the case.

A photo showing that two bullets in a single case is not possible.

I pulled the bullets in the photo above from two cartridges using an inertia bullet puller. Both had exactly 5.4 grains of Accurate No. 5 propellant, which is what I intended. These are the pulled bullets on top of their cartridge cases:

125-grain powder coated bullets pulled from their cases and then placed back on top of their cases.

After I pulled the bullets and put the powder back in each case, you can see the level at which the right amount of propellent (5.4 grains) sets in the case.

5.4 grains of Accurate No. 5 in 9mm cartridge cases.

I wondered: Would a double charge (i.e., 10.8 grains of Accurate No. 5) fit in a cartridge case without it spilling out of the case? The answer is yes. I took the powder from one case and poured it in the other. The case can easily hold 10.8 grains of Accurate No. 5. Take a look:

10.8 grains of Accurate No. 5 in a 9mm cartridge case.

It would be better if the powder was bulky enough that it would spill over the case rim if I double charged it. I know that my 9mm Unique load sits higher in the case (my Unique load for the 125-grain bullet is 5.0 grains).

Trickling 5.0 grains of Unique onto the powder scale.

Here’s what 5.0 grains of Unique looks like in a 9mm case:

5.0 grains of Unique in a 9mm cartridge case.

The question then was how much Unique can a cartridge case hold? I was specifically interested in determining if a double charge of Unique would overflow the case. To answer this, I completely filled a 9mm case with Unique and weighed that amount of propellant:

A 9mm cartridge case completely filled with Unique.

I weighed the amount of Unique held by a completely-filled 9mm cartridge case. The filled 9mm case held 7.9 grains of Unique.

Weighing the Unique held by a completely-filled 9mm case.

A completely-filled 9mm cartridge case can hold a hair over 7.9 grains of Unique propellant.

A double charge of Unique would be 10.0 grains. I concluded that a double charge of Unique would overflow the 9mm case, and this would provide an additional safeguard against an inadvertent double charge. I was careless enough to not notice a case double-charged with Accurate No. 5. I’d like to think I wouldn’t be careless enough to miss powder spilling out of the case, as would occur with Unique. The next time I load 9mm ammo, it will be with Unique.

You might be wondering about the numbers here. Bear in mind that Unique is a less dense propellant than Accurate No. 5. 10.0 grains of Unique occupies more volume than does 10.8 grains of Accurate No. 5.

The challenge now is what to do about the approximately 1400 rounds of 9mm and .45 ACP I already have loaded on the Lee Turret press. I thought I might be able to quickly screen the rounds by weight, but that’s not going to work. The weights of the powder, the brass case, and the bullet all vary, with the bullet (as the heaviest item) having the greatest variation. On the 9mm cartridges, I found that the weight variation of the completed 9mm cartridges varies from 192 grains up to 198 grains. The powder charge is 5.4 grains. If a cartridge weighs 198 grains, would it just be at the upper edge of the weight distribution with the correct single charge, or would it be a 192-grain cartridge with a double charge? It’s even worse on the .45 ACP rounds, because the weight variability of the completed cartridge is more than the 9mm, and those powder charges are in the range of 5.0 grains or 5.4 grains (they are lost in the case compared to 9mm ammo). I can’t take the chance that there’s another double charge in there. I’m breaking down and checking every cartridge. It’s a lot of work, but it’s better than blowing up a gun.

This is the .45 ammo I loaded on the Lee turret press. It’s 700 rounds. I have another 700 rounds of 9mm ammo similarly loaded.

You might be wondering what it’s like to get back on the range after blowing up a gun. I was afraid I might return with a very serious flinch (you know, when you jerk the gun in anticipation of it firing). I’m happy to report (and maybe brag a little bit) that I’m just fine. I had my 9mm S&W Shield out with ammo that I tore down, checked, and reloaded, and I also had my Colt Python (in which I shot .38 Special wadcutters).

An S&W 9mm Shield target shooting the 5.4 grain Accurate No. 5, 125-grain powder coated bullet load described in this blog.

A Colt Python target shot with 148-grain powder-coated wadcutters. I’ve done better and I’ve done worse.

At this point, I’m convinced that I screwed up and double-charged the 9mm round I wrote about last week. TJ (of TJ’s Custom Gunworks) disassembled the gun and pulled out the case you see in the photo at the top of this blog. There was a lot of pressure in there (about 10.8 grains of Accurate No. 5’s worth, actually). Like I said in the earlier blog, it’s an opportunity. More good news is the barrel wasn’t damaged. Even more good news is that TJ is doing an action and reliability job on my 1911. TJ is replacing the two piece guide rod (two-piece guide rods are a solution to a problem that doesn’t exist) and doing a few more good things to this pistol. I’ve already purchased and received replacement grips and a new 9mm magazine. I’ll provide an update in a couple of weeks after I get the 1911 back, and I’ll do another blog on what it’s like disassembling and reassembling 1400 rounds of reloaded ammo.

Stay tuned!

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By Joe Berk

It occurred in an instant, on the fifth and last round in the magazine. It was as if a cherry bomb had gone off in my face. I heard a voice yell “whoa!” and I realized the voice was mine.

I stared at the smoking Springfield Armory 9mm 1911 in my hands, waiting for the pain, the blood, and whatever might follow. My hands, still wrapped around the grips, were stinging. I knew something bad happened, but I didn’t know how bad it was and I wasn’t especially looking forward to finding out. My gun had blown up. The entire gun was smoking and smoke continued to waft from places it wasn’t supposed to: The grips, the line between the frame and the slide, the trigger, around the hammer, and the ejection port (which was closed; at this point, I didn’t know if there was a live round in the chamber). Gray smoke curled out everywhere.

I slowly relaxed my grip and looked at my hands. There was no blood, but my palms stung like they had been slapped with a baseball bat. As I eased my hold, the 1911’s left grip fell away in two pieces (as you can see in the photo at the top of this blog). There were no cuts and there was no bleeding, but I had powder tattoos all over both hands. I returned my focus to the gun. It was still smoking. It smelled funny, too. Was that burnt flesh or just the powder and residual oil?

The first four shots from that magazine were delightfully tight, and I ordinarily would have felt good about seeing that. On each of the preceding four shots (and the fifth one, for that matter), the front sight had been outlined against the blurred rear sight and the bright orange muzzle flash, the way things are supposed to look when the hammer drops.

The first four rounds were forming a nice group. The fifth was a disaster.

I was still afraid to look at my hands. My face was now tingling and I knew I’d caught something. I had safety glasses on and I could see okay; that was good. I worked up enough courage to put the gun down and look at my hands more closely. They seemed okay. I knew from previous bad things happening that sometimes you don’t feel anything for a few seconds (the golden minute, I think they call it), but I looked again and I was okay.

The 1911’s right grip appeared to be intact (but it wasn’t; more on that in a second). The slide was locked forward. I tried to pull it back but it would only move about an eighth of an inch. I pressed the magazine release and nothing happened. I pulled on the magazine and it came out. It was mangled; the front was bent in and the follower angled upward. I still wasn’t sure if there was a live round in the chamber. I cocked the hammer and dropped it a couple of times…and there was nothing. I concluded it was safe to put the 1911 in its case. I scooped up my marbles and left. I didn’t even pick up my brass, and this was Remington brass that had only been reloaded once…that’s how shook up I was.

When I got home, I looked in the mirror. I had one little spot on my right cheek that bled and had already stopped (I’ve done worse shaving). I washed my hands to get the powder residue off (that took a while). There were no cuts. Dodged a bullet, I did. Figuratively and literally.

Once home, I examined the 1911 more closely. The trigger was too far forward in the frame. The event probably screwed up the trigger mechanism. The right grip, which I thought was okay, had a hairline crack along its length. Not that it matters; you can’t buy just one grip (you buy them in pairs). The slide would not move to the rear more than a little bit; it was not coming off the gun.

The trigger moved far forward. You can see the outline on the trigger denoting where it was normally positioned.

The left grip fell off the gun when I released my grip. The right grip had cracked, but it remained in place.

What could have caused this? There are a lot of possibilities. The first (and most likely) is that I double charged a cartridge case when reloading. In other words, I put twice as much propellant in the case as I should have. Of all the reloading equipment I’ve ever used, it’s easiest to do this on the Lee turret press I’ve been raving about. I’m not badmouthing Lee or their turret press; I’m simply making an observation. If that’s what happened, it was entirely my fault.

I could have fired a squib load, had a bullet lodge in the bore, and then fired another bullet on top of it. I’m pretty sure that is not what happened because of the holes on the target. There are four clean holes from the first four rounds, and one lower, oblong hole from the fifth round (when the gun blew up). You can see this on the target above. The bullet didn’t have as much energy behind it and it had started to tumble.

I could have experienced a case failure in which the rear of the case tore off, which would have allowed the hot gases to impinge on the gun internally. There’s some evidence to suggest this. I can look into the bore and see that the cartridge case is still present, but the interior of the case is partly torn away. The lower third of the case’s base is gone (the upper two thirds are present). In the area where the case’s base is gone, I can see the breech face and the firing pin. I later found part of the cartridge case inside the magazine.

This was a tough photo to get (mea culpa on the image quality). You are peering down the barrel from the muzzle end. The upper arrow points to what’s left of the cartridge case; the front of the firing pin is visible. The lower arrow points to the breech face.

The gun could have fired out of battery. That is to say, it may have fired without the slide being fully forward. I can move the slide back about 1/16-inch, cock the hammer, and the trigger will release it. I don’t know if it is doing that because the internals are damaged, or if it could do it before the event. Or, there could have been grit in the chamber that prevented the cartridge from chambering completely. When I look into the bore, I can see residual blue powder coating from the bullet that seems to be lodged between the case mouth and the forward edge of the chamber.

I cast around on the Internet a bit and I found several references to the 9mm 1911 Springfields having tight chambers. I know mine has a very tight chamber. Maybe a cartridge wasn’t resized completely and it failed to completely chamber? If that happens, the slide won’t go all the way forward and the gun shouldn’t fire so I don’t think that’s likely, but who knows.

After I returned home, I examined the magazine again and I could see what I thought was an imprint of the primer on the magazine. I shook the magazine and felt something rattling around inside. It was the primer. It had been flattened, and there was a hole where the firing pin had struck it. I’m guessing the hole was caused by the excess pressure.

A mangled magazine. The left arrow points to the primer imprint. The right arrow points to the distorted follower.

The primer and a bit of brass residue. These were inside the magazine.

An inside view of the primer. Note the circular cutout where pressure sheared the brass against the firing pin hole.

My Springfield 1911 is toast, at least for a while. I have two ways I can go on this (well, three, if you count scrapping the 1911 altogether, but that’s not a choice I want to consider). One option is to return the gun to Springfield Armory, but I don’t want to do that. If the failure was a problem with the gun, I don’t want to have the same guys who screwed it up attempt to fix it. Every gun I’ve ever bought from Springfield has required at least one warranty repair (including this one, but for a different issue). Two of my friends bought 1911s from Springfield and they’ve had to go back for warranty repairs (one had to be returned twice when they didn’t fix the problem the first time). I don’t know what Springfield’s warranty repair turnaround times are these days, but it’s probably measured in weeks or months. The last thing that ruled out a warranty repair was that this event occurred with my reloaded ammo and that voids the warranty. I’m not in denial here; it is likely my reloaded ammo is the reason this happened.

Nope, I’m going to go with the approach that’s always worked for me. It’s the silver lining in this sad tale (that and the fact that I wasn’t injured). I’m bringing the 1911 to TJ’s Custom Gunworks tomorrow. I’ve already talked to TJ and he tells me my 1911 can be repaired. The repairs will be on my dime, but I know the work will be perfect and I know the gun will literally be better than new. I’ll have TJ do a bit of custom work while he has the gun, too. TJ told me he’ll have to cut slide release off to remove the slide from the frame, and when he disassembles it, we’ll learn more. I’m thinking a double charge is the likely culprit (which would be my mistake), but maybe TJ will find otherwise. I’ll keep you posted.

I had a serious debate with myself about posting this blog. It’s an interesting story; that puts it in the plus column. If I double-charged that case, that’s an admission of carelessness on my part and that puts it in the minus column. In the end, if it helps other people from making the same mistake (assuming the fault lies with me), this blog will have served a purpose and that is why it is here.