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If your case length varies quite a bit, not only will the amount of crimp vary, but the expander won't bell the case mouth as much on the shorter cases either. So, your idea that not enough crimp was causing the problem is probably right. I've never had to trim any of the brass for my auto pistols(9mm,38Super,45ACP), but my .357 & .44 Magnums need trimmed every fourth or fifth reload.
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