Okay, first off, I did make a small error in my first post. I stated to use 0.45" diameter 1/8" thick nitro cards. First of all not all nitro cards are specifically sold as 1/8" some are listed as 0.135" thickness or similar which is really, really close to 1/8" and effectively the same thing and probably slightly more accurate description. Secondly, I am using the 0.45" diameter as an expedient since I not only load the 2-1/2" MagTech brand of 410 brass shotgun shells but also have a large supply of Russian mild steel 3" cases converted from their native Berdan primers to use US standard 209 shotgun primers. And their walls are thinner still then the MagTech brass.
Long story short the 0.45" diameter nitro cards work in all my full length metallic cases. They are just right in the Russian 410 full length steel cases and extra tight in the MagTech 410 full length brass cases. And they also work for black powder 45-caliber which I also run.
For someone who is only loading the MagTech 410 full length brass cases not the Russian 410 full length steel cases and also doing 45-cal black powder =
For Nitro Cards For The Over The Powder Card(s) 0.43" size is the best size, not too small like 0.41" or too large like 0.45" Obviously being too large and having to cram them in is better then too loose and if one has a good compression/wad-seating die setup it isn't much of an issue.
For the felt wads which squeeze down far easier and the over-powder shot card which is at the mouth of the case where the full length metallic cases walls are the thinnest and the internal diameter of such case is greatest I would still strongly suggest the 0.45" size.
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Now as to where to obtain those wads. Yes, it is possible to punch your own out of cardboard with a punch set, I have such a set and have done so just enough to prove to myself it can be done if I ever am unable to just buy them. My time is way more valuable then to do it that way unless absolutely necessary. As to who makes them and where to buy, the primary manufacturer is "CircleFly"(.com) which will only accept orders directly in very large quantity. I've only been able to buy directly twice in my life when I socked in some orders that were above $200 and back then the bar was lower for the minimum order.
The primary outlets that are online order distributors for these wads are:
TrackOfTheWolf(.com) = This is my usual preferred place to buy from most often, they seem to have the largest stockpile of CircleFly wads and go out of stock the least often, reasonable prices and shipping costs. Direct link to their wad section =
https://www.trackofthewolf.com/List/Item.aspx/170 I got that direct link saved in my quick links. Page #4 (scroll down to bottom of page to click to specific pages) is where you will find the 0.43" and 0.45" wads as well as the normal 410-gauge wads which are correct for plastic shotgun shells but too small and loose for a good seal in full length metallic 410 shotgun shells. I think the ones you will want for the 12ga. MagTech shells are right there on the bottom of the first page. I think you want the 11ga. size for those to compensate for the thinner walls of those cases. Again I haven't loaded the thinwall cases in the larger sizes but I ASSume that its the same as with the 410 thin wall full length metallic shotgun hulls that you need a slightly larger wad to get a good seal.
BallisticProducts(.com) = This place has some traditional wadding options like thicker waxed nitro cards for the larger gauges that are not CircleFly products and rarely available anywhere else, so when I order some of that other stuff, combined shipping and getting some CircleFly wads as well is normal.
PrecisionReloading(.com) = Good outfit that also has some stuff that no one else has available so when I order some of that other stuff, again combined shipping advantage means I also get what I need of CircleFly products if they have it.
BuffaloArms(.com) = Sometimes when everyone else including Track of the Wolf is sold out of one of the CircleFly wads I want/need these guys will still have a few bags in stock, less people seem to go here for CircleFly wads rather then the other stuff they sell. Now if you ever decide to load some of your full length brass shotgun shells with real black powder or deal with any other black powder loading these guys are my first stop for pre-lubed wads. They seem to be buying CircleFly fiber wads and some other brands of felt wads and impregnating them with their own black powder lube in-house and then reselling them at a higher price point to cover their labor. Very convenient for real black powder loading where you need lubed wads so you don't have to do all that yourself if you don't want too.
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Okay, now, you will need to press the wads in down on top of the powder. Standard shotgun shell reloading presses provide for this by a long tube that the powder and shot are dropped through. No such provision is made for this purpose on a metallic reloading press with the exception of dies made for compressing black powder when loading real black powder cartridges the old fashioned way. These are unsuitable for pressing the wads down on top of the powder charge when loading 410 full length metallic shotgun shells since their compression stem is not long enough to reach deep down enough inside the case.
One of course could have both a conventional shotgun shell loading press on ones bench side by side with a metallic press and go back and forth between the two using each in combination. Or for the purpose of just seating the wads one can always go full on simple and just use a short rod or dowel of appropriate diameter and a mallet and just tap the wads home, that was my first method.
But for the 410 there is actually a pretty easy solution. You just get a "Lee" brand name "Universal Decapping Die" which is like a $15 die normally might cost a little more right now. Unscrew the top collet nut and pull the decapping pin and flip it around with the blunt end down and the small pin up and reinstall and re-tighten the collet down tight - really tight. Blunt end down like that and it is now a wad seating die for your 410 loading. The larger diameter blunt end of that pin is only like 0.2" diameter which is a little on the small size but it works okay. To go further you can have someone who has access to a lathe take some simple rod stock and turn a replacement pin that has a larger diameter of about 0.40" or so and then steps down to a short button of that same 0.2" diameter at the top to be mounted in the collet at the top of the lee die. You can also get a 1/4" thread size machine screw of the right length with one of those tapered flat heads and chuck it up in a hand drill to spin it and take a hand file to hold up against it as it spins and reduce the head diameter to just right (about 0.40" in my experience) and then switch it around in the drill and the threads down on the other end till its just a slip fit in the collet on top of the Lee die and mount it up as a larger diameter plunger then just the Lee pin flipped around. Not quite as stiff and strong to get as much solid compression seating as a replacement made from turned rod-stock that is full diameter all the way up to the bottom of the collet where it only reduces for just a short length on the end to fit in the collet.
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Anyway, how I load the 410 shells is on a Lee 4-stage Cast Iron turrent press with a 303-Brit shell holder:
----- Stage 1 = Universal Decapping Die
----- Stage 2 = Lee 45-ACP Carbide Crimp Die with all the guts removed, carbide sizing ring only
----- Prime on downstroke with pistol primer if MagTech brass. Use my 209 priming setup on a single stage press if its a converted Russian case.
----- Stage 3 = Lee Long Rifle Universal Powder Through Die With Lee Pro Auto Disk set for my powder charge.
----- Stage 4 = Wad Seating Die (A Lee Decapping Die Modified As Explained Above)
----- If I am loading smaller bird shot I just Use a Lee Powder Dipper (usually two scoops of one of the larger ones can't remember which off the top of my head).
----- If I am loading high end plated lead BB shot (one of my favorite loads) I have a small diameter metal tube that is just a little larger inside diameter then that shot and cut to length to hold an exact number count just by filling it up with my finger capping the bottom. BB shot stacks in layers of three inside the 410 same as OO buckshot does in the 12ga. and follow up with a Lee powder dipper scoop of Cream Of Wheat (COW) as buffer and tap on the side to vibrate it down into the layered stacks of BBs to make that load a buffered load.
----- If I am loading buckshot (OO minimum to stack in an inline centered row) I stack the balls one at a time with scoops of COW measured with Lee powder dippers in-between the individual balls
----- Last of all of course I cap it off with a thin 0.45 overshot card usually pressed in just with my fingertip and then apply the wax-glue-paste by finger tip around the inside diameter over that card and set it aside to dry.
One nice addition is a small set of stamps and stamp pad to mark those overshot cards so you know what the heck you loaded in them later !!! Exactly what stamps you get and what they mean is up to you just so long as you know what is what.