Some background first.......
I have been loading 357 Sig ammo. It's all law enforcement range brass, virtually all of it once fired. Most of it (99%) is Speer.
A recent batch of brass (5,000 pcs or so) has been giving me fits! About 2-3 pcs out of a hundred have been wreaking havoc with the primer knock out pins in Lee Precision full length resizing dies. I've had 4-5 look like they broke, deep inside the holder pin. Figured they went "crunch" and went somewhere (goodness only knows....)
Through some testing with an RCBS die set (also 357 Sig), I discovered the same thing....... Except, because the RCBS dies are made different (much longer knock out pins, most importantly), I saw that the knock out pin got pulled out of the sizing rod collet. Sticking straight out of the case mouth. And, in the course of inadvertently installing a new primer (the old primer indeed got knocked out), was able to seat it over the pin stuck in the flash hole................
REVELATION!
I now know that the 4-5 "missing pins" from the Lee set pins are indeed stuck inside assembled ammo.
So, here's my question:
What would happen if I dropped one of those rounds (with the primer pin stuck in the flash hole, and new primer in place over it) into a gun, and pulled the trigger?
Would it?:
A) Completely misfire, because the pin is blocking the hole, and no flash would ever get to the powder?
B) The primer would build up enough pressure to blow the pin out of the flash hole, and the powder would ignite?
C) The pressure resulting from the weird B) scenario would cause damage to the shooter and the gun?
D) Or, the pressure would be fine, and the pin would get shot out the barrel with the bullet?
I'm up against pulling about 200 rounds. Not a biggie in terms of safety rules. But am I worrying needlessly?
So, this batch of Speer brass has undersized flash holes.
My work around was to polish the RCBS knock out pin down a thousandth or so (they are normally .060", and I reduced it to .059", and it's highly polished now.)
Thanks in advance for opinions.