I used to use a Lee FCD, but realized that it was just masking the problem. My problem was two-fold:
- I wasn't sorting my brass by headstamp.
- I wasn't belling the cases enough.
Some brands of brass are thicker than others. The sizing die is going to squeeze the brass down to a certain
outside diameter. That means the inside diameter is going to vary with the thickness of the brass. Each brand of dies is going to size to a slightly different OD - this will sometimes even vary with different examples of the same brand of die. Some brands of dies don't do well with some brands of brass. Other brands of dies seem to be able to acceptably size just about anything.
If the inside diameter is too small for the bullet diameter, and you don't bell the cases enough, the bullets seat hard, and deform the case. A little extra belling on the case helps make the bullets seat easier. A good seating die (like the Hornady) that has a sliding sleeve to align the bullet prior to seating also seems to help. I used to bell the cases as little as possible thinking that it would make the brass last longer. I no longer think this is true. I found that I would either lose the brass, or my primer pockets would get too loose before I had neck splits.
The Lee FCD resizes the round after seating, so it will eliminate the problem, but not the cause.