Can you make a wildcat bullet such as the 6 Dasher cartridge without primer, powders and bullets? Absolutely. You can form improved cases without firing in your workshop, so your barrels will not be damaged. Watch this video and see how it is done: 6 Dasher Hydro-Forming Case Demonstration. Forum member Wes J. P1ZombieKiller (aka P1ZombieKiller), a forum member, has created a video that shows how to form Dasher casings using the Hornady hydraulic forming die kit. This kit includes a two part die (body and piston) and a shell holder. You insert a primer into your virgin brass case, then top it off with a fluid such as water or alcohol, and then run the case through the Hydro-forming Die. After a few hard whacks from a hammer, your case will be 95% formed. Whidden Gunworks’ 6mm Dasher hydraulic forming die can perform the same procedure. The Whidden hydroforming die is a favorite because of its high production quality and consistent results. According to our Forum members, this Whidden system is great. Hydro-Forming Step-by-Step Procedure:
1. Insert the spent primer into a new 6mmBR brass casing.
2. Fill with either water or alcohol.
3. Wipe off excess fluid from the case.
4. Place the case in the special Hornady shell holder (no priming hole).
5. Case up into Hydraulic Forming Die.
6. Use rubber mallet to smack the top piston of the forming die three or four times.
7. If necessary, inspect the case and re-fill it.
8. Pour alcohol (or water), into the container.
9. Remove primer (and keep for future use).
10. Blow-dry the formed case. Measure and inspect the formed case. Wes’ method produces very uniform cartridge OALs. He measured ten (10) 6 Dasher hydro-formed cases and got the following results: two @1.536”, two @1.537”, and six @1.538”. Three or four Whacks Will Produce a 95%-Formed Casing
The shoulders of your improved case are blown out by hydraulic pressure using a Whidden hydro-forming die or Hornady Hydro-forming Die. The process is fairly simple. Place an old primer at the bottom of the new brass piece. Fill the case with a little water and then slide it into the special Hornady shell holder that has no hole in the center. Then, you place the case into the forming die. The fun part is now. You gently insert the plunger (hydraulic-ram) and give it 3 or 4 hard whacks (or better still, a dead blow hammer) from the top. Remove the plunger, and you will have a 95%-formed case that is ready to be loaded. Special Shell-Holder
Hornady provides a shell holder that is made specifically for the Hydro Die; it has no hole at the bottom. Insert a spent primer in the primer pocket, and you’re good to go. The solid shell holder and the spent primer work together to prevent water from leaking out of the primer. The shell holder’s design prevents the primer from escaping. It pushes out slightly during this process. The shell holder is designed with a groove that allows the case to slip out even when the primer is a little protruding.
