Replacement dies arrived and installed.
The Expander die plug is a little different looking, but both measure exactly the same.
Same results...
After swapping all dies, setup the same way, same occasional cocking of bullet, and same mark left on case during seating/crimping..
Next, installed original dies in another 4-hole turret plate that I use for separate decapping as well as sizing 32acp, neither of which is critical. That solved the mark left on case issue during seating. Apparently, the 4 hole plate was not perfectly squared or level?
While doing the swap, I made a mistake and installed the 32acp resizing push pin into the expander die. Next test of expanding of course resulted in error. But looking at the extreme expansion, I thought maybe I could go a little more than I was doing. Maybe all I needed was a little more expansion/flaring? Removing resizing pin, readjusted expanding die until I could start bullets a little deeper, and this seems to look good now, and seems to have solved that issue too.
All problems solved using original dies. 4 hole plate and deeper expansion. Anyone need a new set of loading dies cheap?
Here are two photos, the first is a sample of the crimped bullets pulled, to see if you agree that these looked crimped properly for Berry's Plated bullets. (all are crimped the same, but photo gives illusion that they are different). I wanted to crimp them a little extra due to expanding die going deeper, yet still not split the plating. To me, it looks about as heavy as I should go. OAL is .970. The second photo is the different expanding die inserts, which didn't seem to matter.