While shooting my Rossi 92 45 colt with 360 grain bullets I noticed a case bulge about a 1/4" up from the rim. This action was designed for the 454 casull and is said to be able to handle 60k psi. The loads I was shooting are in the 20k range. After getting out my dials I found the bulge to be .005 bigger than the rest of the case. I typically shoot nickel brass only and have never noticed a bulge with 14k psi loads. With these I loaded them in regular brass cases so I would not accidently feed them to the Italian pietta.

Any opinions or advice are greatly welcome.

Edit: this same brass looked fine out of the 454 SRH.

Maybe your COL is just a tad long and you may be getting an early handshake with the lands and groves? As for the brass, not a biggie, IIRC Lee makes a "Bulge Buster" die just for your situation.

So the Rossi is chambered for the 454, it would not be uncommon for there to be some case stretching with a 45 Colt in the chamber, but still be safe to shoot. Look at the reloading manuals or SAAMI site at the dimensions of those 2 cartridges. .2 inches up the case for a measurement point the 454 is speced at .003 inches larger than the Colt then allowing for +/- dimensions I could see another thousandth or more difference.

Like Trouble shooter said Lee makes bulge buster die for removing bulges. full length sizing might also remove the bulge. Downside IMO is reduced case life from working the brass more.

To clarify my Rossi is not chambered in 454. It is 45 colt. They do chamber this rifle in 454 though.