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Yes, that's how this type of expander works for me. My way of describing it is that a regular flair allows the bullet to tilt to one side of that flair. An M- die style expander allows the bullet...

It really doesn't sound that way. The first section of the expander is .401 dia x about .300-.400 long. The second section is .405 x about .100 long. Using only 1/2 - 2/3 the length of this second...

I don't think your problems are case fill, powder positioning or stabilization....Maybe the gun is only capable of 3-4" at 50ft.

I would recommend getting a 500 count box of 200gr SWC. Make sure...

Is it the same hammer as a 929? (Several of those hammers are available on that auction site.)
That said, I have a 929 and the DA trigger is a good strength trainer, but probably not the greatest DA...

To stop corrosion and condensation you just need a slightly elevated temperature. "Golden Rod" dehumidifiers for gunsafes work this way. They don't remove moisture, they elevate temperature a few...

If the end shake is cured by a shim or by stretching the yoke, what would the cylinder gap be? The barrel may need to be set back too.

Keep in mind that guns varied within the tolerances when...

Off-center is very typical. Hitting right in the middle would be the exception.

Take 50 of your loaded rounds and put them in an empty ammo box. Run your fingertip over the primers and feel for...

If you are convinced the junk you are scraping off the top is actually lead, then save it in a tin can and drop it into your next smelt.

I cast with clean ingots in my basement with a vent fan. I...

You could lube your raw boolits before sizing them. Just a swirl in LLA or even JPW will help lessen the amount of force it takes to size in your size die.

I was sizing some 311316 today and...

How tall is the rear sight? Can you lower it?

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Get some readers. The sight picture should be clear. Target blurry is OK. Go to the drug store and try all the readers. Hold pill bottles at arms length and read the fine print.

I wouldn't waste...

You can size a few boolits multiple times and get a better idea of your die size. Better yet would be to cast a few pure lead and size those to measure the dies. For small jobs like that I use a few...

I run the heat up until I get a little frosting and then I leave it there. I'd rather cast 800 frosty boolits that are well filled out, than have to sort pistol boolits. It's WAY faster to cast...

Gator checks should be working fine with that .400/.401 shank.

Two things to try.
1) Use a gas check seater before the Lee die. Consider using the gas check seater and skipping the Lee die. Or...

Take your firing pin out and weigh it. A steel pin weighs about 60gr, a titanium pin weighs only 30gr.

Some manufacturers use the lighter titanium pins to pass drop testing.

A steel pin has...

The powders and loads should be fine. Tell us what molds you're using and the diameter you are sizing to.

As far as the gun, how did you measure the throats? Are they all the same, or all...

Spin it with the drill and grind it freehand with the dremel while it's spinning.

Just black the end up with a sharpie. Start grinding near the center and work your way toward the edge. Leave a...

Don't worry about loosing the hardness of the cut pin. Annealed steel is plenty hard compared to the lead that is pushing it down. It will still last forever.

Do you own a dremel? How about a 1/2"...

It's probably powder position.

Years ago I was shooting the 95gr Lyman 358242 with bullseye for steel challenge stages. I could hear the audible difference of the first shot from the holster...

I would use a midrange load of W231.

Typically commercial cast has a hard lube for shipping. If you have a problem with leading you could try adding a coat of tumble lube with Lee Liquid Alox.
...

I would copy the hole pattern of a modern S&W. My Model 67 is factory drilled with 3 holes. The forward most hole is about .150 aft of the barrel. If you need any more dimensions, let me know.
...

Could be the barrel is over torqued. Does the front sight look vertical or lean to the left a bit? If it leans to the left, you can have the barrel broke loose from the frame and torqued back in just...

Yes, make your own or buy a real ingot molds. Muffin pans are very inefficient at stacking and nesting. C-channel or angle iron will stack much-much better. (Consider making them the width of an...

How much experience do you and your brother have with S&W revolvers? What you are seeing on a Double Action revolver may be a non-issue or....maybe it is.

Do you and your brother have only this...

I don't think we all understand the potential issue you are referring to.

You say "back and forth" , but then talk about the index gear on the ejector rod???

Back and forth (forward/aft) as you...