Nice work. Your findings are largely the same as mine using a genuine Waltz tool.
One problem with wet pack testing projectiles is that the density of wet paper is way higher than any animal that you are going to be shooting with a .22LR, so take the bullet performance as a comparator only, not an absolute measure of performance. I too found that the lead harness has a massive effect on expansion, and once you reach a certain point in the size of the HP you put into the projectile, hardness has way more effect on expansion than any further increase in the size of the HP you put in with the tool.
I also saw little in the way of real-world accuracy improvement after sizing hunting grade ammo. Yes, if you are looking for the last 0.5% accuracy out of high-cost target ammo, then it is probably worth it. But, one big plus is that no ammo I put through the Waltz tool shot worse after sizing and re-HP'ing than it did out of the box.
So, the real advantage of this tool for me is that I could pick up 10,000 rounds of CCI Standard Velocity solids (which shoots well through all my guns), at a low price, and HP them for better hunting performance. The tool paid for itself in no time.
I can process a 500-round brick per hour through the tool if I put my mind to it, provided I am not re-boxing it back into the factory packets. This includes cleaning the tool after every 50-round box to remove the wax build up from inside the tool. I just drop the HP needle out and push a .22 nylon brush through the dye to clear out the wax. A failure to do this will ultimately result in a crushed round. To reduce wax build up in the tool, put the ammo in the fridge for an hour before you resize it to harden the wax.
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