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Mastering Reloading for the .40 S&W: A Comprehensive Guide

Reloading ammunition offers significant advantages for shooters, particularly those who frequently practice or compete. Among the many calibers suitable for reloading, the .40 S&W stands out as a popular choice, balancing power and manageability. This comprehensive guide delves into the intricacies of reloading .40 S&W ammunition, providing you with the knowledge and expertise to create custom loads tailored to your specific needs. We aim to equip you with the understanding to safely and effectively reload .40 S&W, enhancing your shooting experience while saving money. From selecting the right components to mastering the reloading process, we cover every crucial aspect.

Understanding the .40 S&W Cartridge

The .40 S&W (Smith & Wesson) cartridge was developed in the late 1980s as a compromise between the 9mm and .45 ACP. It was designed to offer a higher velocity and flatter trajectory than the .45 ACP while maintaining a manageable recoil. The .40 S&W quickly gained popularity among law enforcement agencies and civilian shooters alike, becoming a standard for duty and self-defense handguns.

The cartridge’s dimensions are crucial for reloading. The .40 S&W uses a 0.40-inch diameter bullet and has a case length of 0.850 inches. Understanding these specifications is essential for selecting the correct reloading components and setting up your equipment properly. Cases are typically brass or nickel-plated brass, each with different properties that affect reloading.

Why Reload .40 S&W?

Reloading .40 S&W ammunition offers several compelling benefits:

Cost Savings: Reloading is significantly cheaper than buying factory ammunition, especially for high-volume shooters.
Customization: Reloading allows you to tailor the ammunition to your specific firearm and shooting needs, optimizing for accuracy and performance.
Component Control: You have complete control over the quality and type of components used, ensuring consistent and reliable ammunition.
Increased Accuracy: By carefully selecting components and adjusting powder charges, you can create ammunition that is more accurate than factory loads in your firearm.
Availability: During ammunition shortages, reloading ensures you can continue shooting by sourcing individual components.

Essential Reloading Equipment for .40 S&W

To begin reloading .40 S&W, you’ll need the following essential equipment:

Reloading Press: A single-stage press is suitable for beginners, while progressive presses are more efficient for high-volume reloading.
Dies: A .40 S&W die set typically includes a sizing die, a seating die, and a crimping die.
Shell Holder: A shell holder specific to the .40 S&W cartridge is needed to hold the case during the reloading process.
Priming Tool: A hand-priming tool or a priming system integrated into the reloading press is required to seat new primers.
Powder Scale: An accurate powder scale is essential for measuring powder charges precisely.
Powder Measure: A powder measure dispenses consistent powder charges.
Calipers: Calipers are used to measure case length and overall cartridge length, ensuring they meet specifications.
Case Tumbler: A case tumbler cleans and polishes brass cases, improving their appearance and functionality.
Loading Blocks: Loading blocks hold cases upright during various stages of the reloading process.
Safety Glasses: Eye protection is crucial to prevent injury from flying debris or powder.

Components for Reloading .40 S&W

The four primary components for reloading .40 S&W are cases, primers, powder, and bullets.

Cases: Brass cases are the most common and can be reloaded multiple times. Inspect cases for cracks, dents, or other damage before reloading.
Primers: Small pistol primers are used for .40 S&W. Choose a primer brand and type that is recommended for your powder and bullet combination.
Powder: Several powders are suitable for .40 S&W, including Hodgdon Universal, Accurate No. 5, and Alliant Power Pistol. Consult a reloading manual for recommended powder charges.
Bullets: .40 S&W bullets are typically 0.400 or 0.401 inches in diameter. Common bullet types include jacketed hollow points (JHPs), jacketed flat points (JFPs), and lead round nose (LRN) bullets.

The Reloading Process: Step-by-Step

Reloading .40 S&W involves several key steps:

Case Preparation: Clean and inspect brass cases. Tumble them to remove dirt and residue.
Sizing and Decapping: Use the sizing die to resize the case and remove the spent primer.
Priming: Seat a new primer into the primer pocket using a priming tool or press-mounted priming system.
Powder Charging: Dispense the correct powder charge into the case using a powder measure or by weighing each charge individually. This is a critical step; double-check your powder charges!
Bullet Seating: Seat the bullet to the correct depth using the seating die. Consult a reloading manual for recommended seating depths.
Crimping: Crimp the case mouth around the bullet to ensure a secure hold. Use the crimping die to apply the appropriate amount of crimp.

Safety Precautions When Reloading

Safety is paramount when reloading ammunition. Follow these precautions to prevent accidents:

Always wear safety glasses.
Follow reloading manual data precisely.
Never exceed maximum powder charges.
Double-check powder charges to prevent overloads or squib loads.
Store primers and powder in a cool, dry place away from heat and open flames.
Keep your reloading area clean and organized.
Never smoke or eat while reloading.
If you are distracted, stop reloading.

Choosing the Right Reloading Press

Selecting the right reloading press is a crucial first step. There are two main types: single-stage and progressive.

Single-Stage Press: This type performs one operation at a time. It’s ideal for beginners because it allows for careful monitoring of each step. It’s also suitable for reloading small batches or for developing custom loads.
Progressive Press: This type performs multiple operations simultaneously, significantly increasing reloading speed. It’s best for high-volume reloaders who need to produce large quantities of ammunition quickly.

For beginners reloading .40 S&W, a single-stage press is highly recommended due to its simplicity and safety advantages. As you gain experience, you might consider upgrading to a progressive press for increased efficiency.

Selecting the Right Dies for .40 S&W

Dies are essential for shaping the brass case and seating the bullet. A typical .40 S&W die set includes a sizing die, a seating die, and a crimping die.

Sizing Die: Resizes the case to ensure it fits properly in the firearm’s chamber. It also deprimes the case by removing the spent primer.
Seating Die: Seats the bullet to the correct depth. Some seating dies also allow for crimping.
Crimping Die: Applies a crimp to the case mouth to secure the bullet. Crimping is especially important for semi-automatic pistols like those chambered in .40 S&W to prevent bullet setback during feeding.

When selecting dies, choose a reputable brand known for quality and precision. Carbide dies are preferred because they don’t require lubrication, making the reloading process cleaner and easier.

Primers: The Ignition Source

Primers ignite the powder charge, initiating the firing sequence. The .40 S&W uses small pistol primers. There are different brands and types of primers available, each with slightly different characteristics.

Standard Primers: Suitable for most reloading applications.
Magnum Primers: Designed for use with magnum powder charges or in cold weather conditions.

It’s important to choose a primer that is compatible with your powder and bullet combination. Consult a reloading manual for recommended primer types.

Powder Selection for .40 S&W

The type of powder you choose will significantly impact the velocity, pressure, and accuracy of your .40 S&W loads. Several powders are well-suited for .40 S&W, including:

Hodgdon Universal: A versatile powder that works well in a variety of handgun calibers.
Accurate No. 5: A popular choice for .40 S&W, known for its consistent performance.
Alliant Power Pistol: Delivers high velocities and is a good choice for self-defense loads.
Winchester AutoComp: Designed for semi-automatic pistols, providing clean burning and consistent performance.

Always consult a reloading manual for recommended powder charges and follow the data precisely. Start with the minimum recommended charge and gradually increase it until you achieve the desired velocity and accuracy, while carefully monitoring for signs of overpressure.

Bullet Selection: Optimizing for Performance

The bullet is the projectile that is fired from the firearm. .40 S&W bullets are typically 0.400 or 0.401 inches in diameter. Common bullet types include:

Jacketed Hollow Points (JHPs): Designed for self-defense, JHPs expand upon impact, creating a larger wound cavity.
Jacketed Flat Points (JFPs): Offer good penetration and are often used for target shooting and hunting.
Lead Round Nose (LRN): Inexpensive and suitable for target shooting, but not recommended for self-defense due to their tendency to over-penetrate.
Total Metal Jacket (TMJ): Encapsulated in copper, these reduce lead exposure.

Advanced Techniques: Fine-Tuning Your Loads

Once you’ve mastered the basics of reloading .40 S&W, you can explore advanced techniques to fine-tune your loads for optimal performance. These include:

Case Weight Sorting: Sorting cases by weight can improve consistency and accuracy.
Primer Pocket Uniforming: Uniforming primer pockets ensures consistent primer seating depth.
Neck Tension Adjustment: Adjusting neck tension can affect bullet seating and accuracy.
Chronographing: Using a chronograph to measure bullet velocity allows you to fine-tune your powder charges for consistent performance.

Troubleshooting Common Reloading Issues

Even with careful attention to detail, you may encounter problems during the reloading process. Here are some common issues and their solutions:

Primer Seating Problems: Ensure the primer pocket is clean and free of debris. Use a primer pocket uniformer if necessary.
Bullet Seating Problems: Check the seating die adjustment and ensure the bullet is properly aligned.
Crimping Problems: Adjust the crimping die to apply the correct amount of crimp. Over-crimping can damage the case or bullet.
Inconsistent Powder Charges: Calibrate your powder measure and ensure it is dispensing consistent charges.

Reviewing the Lee Precision .40 S&W Die Set

The Lee Precision .40 S&W die set is a popular choice for reloaders, known for its affordability and ease of use. This set includes a carbide sizing die, a bullet seating die, and a crimping die. It also includes a universal shell holder and a powder dipper.

User Experience & Usability: The Lee dies are straightforward to set up and use. The instructions are clear and easy to follow, making them suitable for beginners. The carbide sizing die eliminates the need for case lubrication, simplifying the resizing process. The bullet seating die allows for precise seating depth adjustment, and the crimping die applies a consistent crimp.

Performance & Effectiveness: In our experience, the Lee dies produce consistent and accurate ammunition. The carbide sizing die resizes cases smoothly, and the bullet seating die seats bullets to the correct depth with minimal runout. The crimping die applies a uniform crimp, ensuring reliable feeding and ignition.

Pros:

Affordable: The Lee die set is one of the most affordable options on the market.
Easy to Use: The dies are simple to set up and use, making them suitable for beginners.
Carbide Sizing Die: The carbide sizing die eliminates the need for case lubrication.
Consistent Performance: The dies produce consistent and accurate ammunition.
Complete Set: The set includes everything you need to reload .40 S&W, including a shell holder and powder dipper.

Cons/Limitations:

Durability: While the Lee dies are well-made, they may not be as durable as some higher-end options.
Adjustment: The adjustment knobs on the dies can be a bit finicky.
No Decapping Pin Retainer: The decapping pin can sometimes loosen during use.

Ideal User Profile: The Lee Precision .40 S&W die set is best suited for beginner reloaders and those on a budget. It’s a great option for reloading small to medium quantities of ammunition.

Key Alternatives: RCBS and Hornady offer .40 S&W die sets that are generally considered to be of higher quality and durability, but they also come at a higher price point.

Expert Overall Verdict & Recommendation: The Lee Precision .40 S&W die set is a solid choice for reloaders seeking an affordable and easy-to-use option. While it may not be the most durable die set on the market, it offers excellent value for the price and delivers consistent performance. We recommend it for beginners and those on a budget.

Tips for Accurate .40 S&W Reloads

Achieving accurate .40 S&W reloads requires attention to detail and consistent practices. Here are some tips to improve your accuracy:

Use High-Quality Components: Invest in quality bullets, primers, and powder.
Weigh Powder Charges: Weigh each powder charge individually for maximum consistency.
Seat Bullets Consistently: Use a bullet seating die to seat bullets to the same depth every time.
Apply a Consistent Crimp: Use a crimping die to apply a consistent crimp to the case mouth.
Test Your Loads: Test your reloads at the range to evaluate their accuracy and performance.

Is Reloading .40 S&W Right for You?

Reloading .40 S&W can be a rewarding and cost-effective way to customize your ammunition. By understanding the reloading process, selecting the right equipment and components, and following safety precautions, you can create accurate and reliable ammunition tailored to your specific needs. Whether you’re a competitive shooter, a recreational shooter, or a self-defense enthusiast, reloading .40 S&W can enhance your shooting experience and save you money.

If you’re ready to take your shooting to the next level, consider exploring the world of reloading. Share your experiences with reloading .40 S&W in the comments below or contact our experts for personalized guidance on getting started.