So I'm using some of my cast 9mm bullets from the Lee 125g round nose mold powdercoated and sized .356, longshot powder, with a Winchester primer. Hogdons website lists 5.0g @ 1.125 OAL for start with a 125g LCN, and 5.2g @ 1.150 OAL for start with 130 BERB. The actual weight of these bullets falls around 128 and I have shot them with 5.0g @ 1.125 with no problems.

My issue is this, when I was sizing this last batch of 60 or so bullets after powder coating, the sizing die must have gotten tweaked and I didn't realize and what happend was the bullet being sized being pushed into the base of the one ahead of it, flattening the nose a little and widening the front end. So, I seated one and tested for fit in the chamber of my SW5906 @ 1.125 OAL and it wasn't fully into the chamber. I had to shorten it to 1.100 to get it to fit and let the slide go completely closed. I checked this round in an XD chamber and it was too long for it even at 1.100.

So, the question is, would being seated this depth be safe pressure wise with the 5.0g start charge or should I just put the affected bullets in the scrap bin to be remelted and recast  ?

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Taught always to error on the side of safety...

sounds like not many, I'd start with new and melt.

Pressure wise you are not near the upper end anyway, I shoot a few to test the seating depth!  Remember that SAAMI has a very low pressure set for 9mm as compared to the C.I.P. standards.

Quote9mm Plus Pressure Plus  Charles E. Petty
Basicly..... Is it worth it to beat the snot out of your firearm for a little extra?

The current SAAMI (Sporting Arms and Ammunition Manufacturing Institute) standard for 9mm Luger ammunition specifies a maximum product average chamber pressure of 37,400 p.s.i., but, the +P+ loads exceed this by a substantial margin. A limit of 42,000 p.s.i. has been proposed for this ammunition. For comparison, proof load pressure (nominal average) is set at 49,800 p.s.i. Now the situation is even further confused, for Remington has begun to market +P 9mm Luger ammunition with a proposed pressure limit of 38,500 p.s.i. To clarify, +P ammunition is available for commercial sale while +P+ loads are not.

Thanks for the replies and the pressure info Shadow. I think I'll load another couple and shoot them and see what the cases look like. I'll let you guys know how it works out!