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This has happened to me in some other calibers, though not in .45 Colt. I have read that normal seasonal temperature heating/cooling cycles will harden brass gradually over several cycles. Maybe this is true, maybe it isn't, but I know that some brass that was just fine when I loaded it that was left to sit a couple of years before firing split much as you have indicated. Maybe that's your problem. Give some thought to the history of this particular lot of brass. Therein may lie your answer.

RonF
 
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