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vagunner, I use only the expander die; I do not have a powder through expander. It does sound like you are using a taper crimp die, which I do not have yet (I've ordered one). I've tried the expander set to barely any flare to a lot of flare, makes no difference. What do yours look like BEFORE you run them through the taper crimp die? I've ordered a taper crimp die and a powder through expander (I want to keep my powder cop die, but I have only 5 stations, so the Expander die will have to go). Also, what diameter is your brass after resizing (toward the bottom and toward the top)? If I didn't know any better, I'd think that the resizing die was too tight...
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