I would also seat the bullets out far enough to just jam in the rifling when you shut the action. This will help initial pressures spike a little and stop the chance of another case separation if you shoulders are off by trapping the cartridge base against the breach.

I just got my EABCO 6.5-06 A.I. barrel for my ENCORE and am using CH4D dies. The A.I die isn't worth a crap in the forming department. I tried necking up 25-06 brass, and was rewarded upon firing with (out of 12)..6 split shoulders and a head separation (that one hurt). Because it's an Encore, camming a case in the chamber prior to fireforming isn't an option.

Attempt #2 was the use of 270 brass (a little long, I know..I trimmed them). A 270 case will almost fit in the chamber(???!!!!). I then necked up the 270's to 7mm in a 7 Rem mag die, then attempted to slowwwwwly neck the case down in increments until the case headspaced on the neck-shoulder junction. Crooked and off-center necks. I figure this is from trying to "neck size" in the A.I. die where the shoulder diameter is so much larger than the 270 case. So I just ordered a standard 6.5-06 neck sizing die hoping that it will keep the neck reasonably centered when necking back down from 7mm. Am I on the right track??

Paul,
I would say you're on the right track. You've made this into more work than necessary. That's one of the attractions of the Ackley Improved cartridges. Just size them to fit your chamber, charge them with a load known to be safe and touch it off, it doesn't get much easier. As plentiful as 30/06 brass is, that's what i'd be using. You want to make the first firing a fairly stout one, so the brass properly conforms to the chamber, as in no headspace problems. I read posts about all the trouble fireforming is, it's no more of a problem than loading for standard cartridge. Just load them and fireform while you are hunting. I hope this helped.
Stepchild

This is gonna sound weird but it's the truth... not enough chamber pressure on the first firing is probably spitting your cases. The split shoulder is the give-away. For some reason the brass lets go. You need max or near max loads, preferably from the fastest powder in your standard 6.5-06 data. Once the cases are fireformed, this problem goes away. I've had the same thing happen and cured it upping the pressures.

Whenever we neck up or down,we work harden the brass in the neck,and we get split necks when fired.You must anneal"heat treat"the necks and the neck spliting will stop.

True but even properly annealed brass will split in the shoulder if the AI fireforming pressures are too low.

Tigertate...you're the winner. The cases look like crap, but I'm seating the last few thousanths by closing the action and "jamming" the bullet against the rifling. Today, I was 5 for 5 with beautiful cases. Thanx all for the advice. (I'm still gonna get the 6.5-06 sizer, though)

Glad your problem is solved. I hate how annoying a new toy can be when it won't do right.

You don't need a 6.5-06 sizer,..just buy the 6.5 expander mandral from K&M and neck up 25-06 brass right in your press. IF THE CHAMBER IS CORRECTLY REAMED,..then you will feel the shoulder crush against the chamber shoulder even without a bullet in it. Just seat into the lands .005-.008" and set off a mid range load of something like 4895 or similar,..and the cases will be perfect. No need to spend the money on another die when the Expander mandral and threaded holder from K&M work PERFECT for sizing up from 25-06 brass. That's all I do and they come out beautiful with the coloration around the neck/shoulder showing that the brass growth was all from the front of the case,..and not the case head area.

I just received the last 6.5-06 (standard) Redding die from Midway and THAT is the ball$. It keeps the neck centered on that 270 brass perfectly. Works like a charm.

I don't think an Encore chamber can be "correctly" reamed to an AI.

Make the cases out of 280 Remington brass. Don't use nickel cases.

Why not? I don't quite follow you. 280 brass (and 270 as well) must be trimmed quite a bit(.054) before I can even start. No thanks..I don't want to trim that much x50 cases. I have some 25-06 brass, necked up to 7mm, then necked down to 6.5mm to form a slight 2nd shoulder. The bullets are then loaded into the rifling. I have 5 fireformed rounds so far using this technique and it seems to work. Can't wait to start shooting targets with the finished brass loaded......Sunday, I think.

Pics of a couple of the fireformed cases. Perfect in my book. Thanks for all the advice.

The 280 brass is .040 longer on the headspace. That will fill up a chamber if it has "30-06" headspace.



Check inside your case with a feeler gage.