Its a sizing die... don't you screw it in to contact the shell holder and then turn it in a little more? Seems to me you couldn't have this issue by screwing the die in too far.

Im sure its the dummy pulling the handle

That is a rough cut way of doing it, but far from optimal. The best way is to use a headspace gauge and adjust the die until the shoulder is set back 0.0015" - 0.003". Setting back more than that can cause excessive headspace, which may cause fail to fires, excessive thrust on the bolt face, or in more severe circumstances the brass to split. At a minimum, excessive sizing cases more work hardening of the brass with attendant shorter life of the brass and depending on the case, more trimming required.

Here is a link to a set to measure fired brass and an excellent investment. These are easy to use.

http://www.midwayusa.com/product/479704/...with-comparator

Im not going to argue and say your way of bumping it back isn't more consistent but I also think your making mountains out of mole hills on the other bit, its not different than firing factory ammo, and the point being that is not what is causing him to rip the 'lip' or rim off the cartridge.

I agree it is not what is causing the OP's problem.

Sounds like he has a bad die, which definitely does happen. I've had a couple through the years.

Sent one back to Redding who replaced it with no charge.

Pitched a bad RCBS die in the recycle bin as I did not even want another of their products.

Forster is my first choice as the expander ball usually produces the least amount of runout, although Redding dies are right on par.

Spot on.

The only effect it could have on the case mouth is to roll the edge, possibly---if the case length is excessive enough.

I'm thinking that the expander ball is too far up into the die and the neck is getting pinched on the way out of the die. Maybe not though...but one way to know is to remove the decapping/expander assembly and see how a case acts when sized with out it. I can't imagine the problem persisting in that scenario, but I suppose it's possible even if I can't imagine it.

I'd bet a six-pack it's a bad die or a misadjusted (or possibly damaged) decapping/expander assembly.

Ok after a bit of persistence I got everything apart.
Here are a couple of pictures of the brass. Note the flattened neck and the mouth of the case is stretched.
But here is the part I can't compute. I had sized almost 20 pieces before I got to this one ?

I'd size a case with just the die body and see what happens.

Give the die to someone you don't like and buy a new one.

Something looks hauntingly familiar in those pics. Is your shell holder popped all the way into the slot on the ram??

May have been answered already, is this a bushing die?

Nope this is a standard Lee resizing die.
I happened to have another new expander. So went back and double checked Lee's directions on setting the resizer. Put it all together and installed it in My RCBS I made it through 5 Pcs before I stuck another one. ... I friggin give up.

/\ /\ /\ /\ /\
THIS....except I don't dislike anyone enough to do that

What shell holder are you running ( # and brand, yes they are different)? I'm looking at the pictures of the case you posted, and that looks like the wrong shell holder and the case going in oblonged. If the case goes in crooked, then it can size it oblong and get that. But if it goes in straight, it will come out straight.

Yeah, that. I was thinking maybe the shell holder isn't popped all the way onto the ram, but maybe it's just the wrong one all together.

Remember that shell holder Numbers vary from manufacturers..... RCBS #3 is a Lee#2 both fitting 308

Looks like a shellholder issue to me

Hmmm... I will look and report back

I think the OP said he sized 20 or so cases before the problems started. If so, that doesn't sound like a shell holder issue. Sounds more to me like the die internals got messed up somehow, even though there isn't much inside that can mess up. This is an interesting puzzle. Can't wait to find out what's going on.

Yeah, it IS interesting.

I wish C would get back to us. How am I supposed to get a good night's rest, not knowing what's causing this??

I have made a bit of progress and have come to a contusion.
I went to Cabelas to pick up some 200 Gr .308 bullets for my 300 Weatherby.
I noticed at the end of the rack they had the Hornady American dies for $28
I figgerd why not give em a shot?
So came home set it up according to directions used a new shell holder in my RCBS.
I resized 50 some odd pieces without a hiccup. So the only change I made was die and shellholder.
I'm going to call it a die issue.

Now.. what I did notice is that the Norma brass was tight enough that on one piece it squalled on the outstroke.
but it didn't stick. I looked and I think some of this brass was fired in an AR
what I thought is that possibly the AR has a bit bigger chamber to handle the 7.62 military ammo?
I do know Mil brass will not fit my Savage 99 ??

So what was the number on the old shellholder?? Either it was the correct one or it wasn't .... That would seem a simple thing to eliminate.

"I'm going to call it a die issue."

We should all meet somewhere, and the OP brings the die and we bring beer, and we can all examine the die. Team building...

A die doesn't case your issue. An improper shell holder making the case go into the die crooked and not having a proper grip on the case rim (because it's the wrong shell holder) causes this issue. If you go back and check your shell holders, I bet you are using the wrong shell holder. Also, check the head spacing on the other cases you sized before this problem happened. The head spacing could be off, and then you will have a problem with chambering and pressure issues.

This should work^^^