I assume the ammo fired from your pistol is bugling the brass to the point you equipment will not take the bulge out? What is your load info? Powder charge, Coal and bullet wight? What Kind of pistol?
For the last 20 years i have used only range pickup brass, Never had to roll size any. 9mm and .40. I find my glocks and XDs have pretty loose chambers, and for the most part eat anything, 1911 and 2011s tighter. On the same note, If im running hot loads, they also tend to start bulging the brass, I was fast to come to the conclusion i dont need to push my reloaded ammo so hard, Backed my loads off to match factory 115 ammo, for 9mm, and Major PF for .40. none of my brass is bulged at all now.
I also inspect ALL range brass before it gets loaded, A lot of guys seem to push pistol loads to the max, Just last week i was at the local range and found about 200 or so 9mm cases, Being a horder, i got excited! Picked it all up, when picking it up i was looking at it, Severely bulged, some even looked like they had stress cracks, Pierced primers, and bad rings, Some of it looked like it was fired out of battery maybe, I junked it all to the scrap bucket. My though was holy Christ, who ever is shooting/Loading this needs to pay more attention to what is going on, wont be long before something bad happens. Maybe the shooter knew it was bad and left it?? The 2nd problem with this is the bad brass could be de primed, cleaned and roll sized, basically making it look like almost new and then sold, In my mind it is junk, and pry not safe.
