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Dundee; trying to use oversize reloading dies to prolong case life in the .40 S&W is truly an act of futility.
First, read the above posts about the difference between a case expanding to fill a chamber and a case bulging where it is unsupported. It is safe to reload brass which has done the first, but bulged brass is a sign of trouble.
Second, if you resize the case to a larger than normal diameter, you may have difficulty in making the bullets stay put. Remember that the bullets are not increased in size. Any bullet set back in a extremely sensitive caliber such as the .40 S&W is very dangerous.
Third, you are going to be strewing the range with poison pills. Your brass, reloaded conventionally after you have reloaded it a few times your way, may well overwork the brass, and cause it to give way.
Fourth, you are making ammo which will work only in your gun, or at least with a chamber as big as your Glocks. This could lead to a jam, if someone else uses your ammo.
Fifthly, full length resizing isn't. The cartridge case just above the webspace doesn't get resized. There was an article about a guy who was using .38 Super brass in a pistol with a very tight chamber. He let some other people use his ammo in their more loosely chambered gun. He wrongly thought that full length sizing would allow him to reuse this brass in his tightly chambered pistol.
Finally, the Hodgdon Powder Company felt compelled to list this in their .40 S&W reloading data section, 1997 Reloading Manual:
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This data is intended for use in firearms with barrels which fully support the cartridge in the chamber. Use of this data in firearms which do not fully support the cartridge may result in bulged cases, ruptured cases, case head separation, or other condition which may result in damage to the firearm and/or result in injury or death of the shooter and/or bystanders.
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Reloading the .40 S&W is, at best, a risky proposition. Your attempt to use lead bullets is foolish, an attempt to have oversize reloading dies constructed is even more foolish.
Cheapo; the working pressure of the .45 Super is 28,000 cup. There is also a 'tactical' load at a lower pressure.
Hope this helps, Walt
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