"i bought this lot of cases brand new. Lot of 50. They have never been cleaned. I opened the box, ran them all through my redding FL resisizing die, trimmed, uniformed primer pockets, charged with about 3 week old powder, and seated my bullet without a crimp."
Exactly. I've had numerous similar mid-body splits with BOTH brand spanking new AND brass that has been fired and reloaded many times.
The cause is a weak point in the brass that fails.
Cartridge brass isn't perfect. The manufacturing process isn't perfect. The reloading process isn't perfect.
Yes, there is evidence of gas leaking out of the crack and into the chamber because that's exactly what happened.
The high-pressure gas pushing out of the cracked area overcomes the resistance of the brass being pushed against the chamber walls.
My guess, though, is that it doesn't happen at the start of the ignition cycle, when chamber pressure is rising, but AFTER peak pressure, when the brass begins to contract away from the chamber walls.
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