Test your defensive ammo! Assume nothing!

I've been working on a new "EDC" in the form of a build based on a 100% serialized frame. My first order of business was to make sure it functioned reliably with FMJ range ammo. No problems there, with 1,000 rounds of common 115-gr FMJ over several range trips. During the last range trip, I tried some defensive hollow point ammo. For the first test, I ran through 20 rounds of Federal HST +P 147-gr. That is the defensive ammo I've had in my factory Glock 19 for years. It fired flawlessly in the P80 EDC build. And it was time to go home at that point.

Today I had a combination of tasks. I added an optic. So I needed to get that zeroed. I also wanted to continue reliability testing with both FMJ and HP ammo. The weight of an optic on the slide can potentially cause issues.
20220929_165235[1].jpg

The optic zeroing and testing went very well.

I got some new 124-gr FMJ ammo to try, and it proved to be reliable with the optic installed.
20220930_105614[1].jpg

I had also recently purchased some Federal HST 124-gr hollow points to test in addition to my existing stash of HST +P 147-gr. I ran 25 rounds of the new HST 124-gr ammo through with zero malfunctions. I forgot to bring a box of the HST +P 147-gr ammo. But then I remembered I had some in my pocket, in my spare mag for my current EDC - a Gen 2 Factory Glock 19. I popped the spare mag in my P80 EDC build and fired 9 rounds. Zero problems. I decided that was enough for now, and I didn't want to "waste" the rest of the ammo in that mag. I dropped the mag and went to manually eject the live round in the chamber.

Rut-roh! The slide wouldn't rack! It was stuck! I mean it would not BUDGE... at all. It felt like it was glued shut! Surely my eyes and hands deceive me. This can't be happening with my "perfect build!" I kept the muzzle pointed down range and tried to rack the slide again. No dice! REALLY?!?? WTF?!?? Tried AGAIN with some real force. NOPE! I'm pretty sure I heard my gun laughing at me!

Naturally, we test defensive ammo compatibility by loading and FIRING it. Usually all of it - whatever we loaded in the magazine. Checking accuracy - POA = POI. Checking reliability in terms of feed, fire, extraction / ejection. We don't want to find out the ammo causes problems when the SHTF. One of the most common issues with Hollow Point ammo is Failure To Feed (FTF). The truncated shape of hollow points may not play well with the barrel feed ramp in some cases.

But, what about manually cycling live rounds without firing them? Manually extracting live rounds? We do it with Snap-Caps during function testing at home. But, I will admit it had not occurred to me to test it with live ammo. But by chance at the range, I tried... and failed.

Finally, I decided to just fire that stuck round (without the mag) and see what happens. Bang and a perfect extraction and ejection of the spent shell. What gives??? It occurred to me that perhaps the 147-gr bullet in the HST +P round is slightly longer, and maybe that's why it was stuck when I tried to manually eject the live round. Time to go home and do some analysis!

I went home. I loaded a mag of regular HST 124-gr ammo and manually cycled it. Like buttah! No problems. I loaded some HST +P 147-gr ammo. Chambered the first round. It fed without a problem. Then I tried to eject it. Problem! Jammed again. I tried again with more force. Jammed!! I tried again using MORE force. Success! It took a surprising amount of force to get the round to eject. What is up with that?? No bueno!

Time for more analysis. "Plunk" test time! The Plunk Test involves removing the barrel and dropping a live round into the chamber. It should drop in easily. You should be able to rotate / spin the round in the chamber easily. And when you turn the barrel chamber-down, the round should drop out.
Plunk-Test.jpg

I compared CCI FMJ 124-gr, Federal HST 124-gr, and problematic Federal HST +P 147-gr. The CCI FMJ and HST 124-gr passed the plunk test easily. However, the HST +P 147-gr.... was what I will call "sticky." If I pressed the round into the chamber, I could turn the barrel upside down and the round would stay in the chamber. Interesting.

Next... Let's get out the digital calipers. I measured the same three rounds - CCI FMJ vs HST 124-gr vs HST +P 147-gr. I made this infographic to demonstrate the differences in length and shape between the three rounds:
Bullet-shape-size-plunk-test-2.jpg

While the HST +P 147-gr is longer than the HST 124-gr, I realized that it couldn't just be the length causing the issue. The CCI FMJ 124-gr ammo was longer than both of them. But, look at the bullet profiles. The FMJ is nearly conical, as is most 9-mm FMJ ammo. The HST 124-gr ammo is fairly tapered, as well. But, you can see that the HST +P 147-gr has a side profile that is straighter... more parallel... not as tapered. Perhaps this is causing the problem with manually cycling / extraction of the live rounds.

The take home message....
Test your defensive carry ammo! Whether your EDC or Home Defense gun is a factory firearm or a PMF (personally made firearm).

Test it in every way. When I previously tested the HP ammo, I fired every round I loaded in the magazine. It was "by chance" today that I decided to stop halfway through a mag and unload the gun. That's how I discovered the issue with the HST +P 147-gr round.

What say you? Comment below!
 
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So than load em and carry them or choot em.

Have you plunked them in your other afm barrels? Another identical barrel from same maker might be slightly different.
 
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So than load em and carry them or choot em.

Have you plunked them in your other afm barrels? Another identical barrel from same maker might be slightly different.
I had this problem with a hoopergunworks barrel....identically. I now have a Lone Wolf barrel and a Wilson Combat barrel that do not have this problem.

Same round.....147gr HST's.

I'm a Machinist, so I had the proper tools for taking accurate measurements. The problem I found was a tapered chamber.
 
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Have you plunked them in your other afm barrels? Another identical barrel from same maker might be slightly different.

You read my mind. Planned to do that next and just finished. I only have 4 builds with aftermarket barrels for now. Actually I have some other barrels that aren't "built," yet. But, I tested the other three that are in current builds.

One passed and two failed the plunk test with this particular 147-gr round.

Interestingly, the two that failed are Zaffiri Precision marked barrels. It is believed that Florida Man Tactical, the maker of the barrel - subject of this thread - is affiliated with Zaffiri... all the same manufacturer. Also 80P Builders is believed to be the same company.

The barrel that passed is in my "Goldi" build that comes from a different company - ArmorAlly.

In the end... what matters is the barrel that I picked for this build intended as a defensive weapon. The others are basically range toys. I can use standard pressure HST 124-gr rounds with it. I plunk-tested Winchester SXTs, and they passed, too. I'm not going to change the barrel in this EDC build just so I can use that ONE type of HP ammo. I'm not "married" to that ammo. :)
 
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I had this problem with a hoopergunworks barrel....identically. I now have a Lone Wolf barrel and a Wilson Combat barrel that do not have this problem.

Same round.....147gr HST's.

I'm a Machinist, so I had the proper tools for taking accurate measurements. The problem I found was a tapered chamber.

So, I'm NOT crazy!?? LOL!
 
Where’s my lab smock?? Lol some good stuff here…and I’m all ears about the ROOK rear rail upgrade. My proven SC build has some trigger ā€œmushā€ on initial take up that may be from the P80 rails as they are described in another thread. Hmm. I might order a ROOK rear rail replacement for it and see if that improves said issue. It sure can’t hurt. Except my wallet. Lol
 
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Where’s my lab smock?? Lol some good stuff here…and I’m all ears about the ROOK rear rail upgrade. My proven SC build has some trigger ā€œmushā€ on initial take up that may be from the P80 rails as they are described in another thread. Hmm. I might order a ROOK rear rail replacement for it and see ft that improves said issue. It sure can’t hurt. Except my wallet. Lol

I don't know if my trigger finger is sensitive enough to feel a difference. But, it made sense to me to fully support the trigger housing with the full contact of the Rook rail vs the little tab on the P80 rear rail module. I had some Rook rails on hand, so I just swapped them out.
 
ā€œSupport can be beautifulā€ lol

So far the only thing I’ve used from ROOK is their stellar dimpled pinsets, and their DLC smooth operator plungers. Why shouldn’t I expect anything less with their rails?
 
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ā€œSupport can be beautifulā€ lol

So far the only thing I’ve used from ROOK is their stellar dimpled pinsets, and their DLC smooth operator plungers. Why shouldn’t I expect anything less with their rails?
Their rails are miniature milled metal sculptures! :)
 
I had this problem with a hoopergunworks barrel....identically. I now have a Lone Wolf barrel and a Wilson Combat barrel that do not have this problem.

Same round.....147gr HST's.

I'm a Machinist, so I had the proper tools for taking accurate measurements. The problem I found was a tapered chamber.

I heard back from Zaffiri:

Thank you for all the information. I have spoken to our barrel production manager, and he is going to dive into this issue. The main problem is that our barrels are made to SAAMI spec which is a standard spec that most companies use for chambers. We are going to do a batch testing to see if some were just out of spec or if the design needs to be changed from SAAMI spec to accommodate those different types of ammo. We are looking into the matter to find a solution or update information on the website. I will update you once we have some more information. Again, thank you for bringing this to light.

Team @ZP
 
I heard back from Zaffiri:

Thank you for all the information. I have spoken to our barrel production manager, and he is going to dive into this issue. The main problem is that our barrels are made to SAAMI spec which is a standard spec that most companies use for chambers. We are going to do a batch testing to see if some were just out of spec or if the design needs to be changed from SAAMI spec to accommodate those different types of ammo. We are looking into the matter to find a solution or update information on the website. I will update you once we have some more information. Again, thank you for bringing this to light.

Team @ZP
It will be interesting to know what is found.
 
OK... Update on what I have found.

First, I stripped the slide and then put the Go gauge in the barrel. The barrel dropped into the slide perfectly. I tried it with a 124-gr HST round... perfect fit. Tried it with a 147-gr round.... no go! And, just from that test, the 147-gr round was difficult to remove from the chamber.
1665268102650.png


Then I used the ammo check gauge on both HST rounds. Both passed.
1665268127620.png


So... What does that tell us? I sent this info to Zaffiri moments ago.
 
Tells you the throat on your barrel/s is too tight and needs to be cut/reamed 1/1000 deeper.
 
I've been working on a new "EDC" in the form of a build based on a 100% serialized frame. My first order of business was to make sure it functioned reliably with FMJ range ammo. No problems there, with 1,000 rounds of common 115-gr FMJ over several range trips. During the last range trip, I tried some defensive hollow point ammo. For the first test, I ran through 20 rounds of Federal HST +P 147-gr. That is the defensive ammo I've had in my factory Glock 19 for years. It fired flawlessly in the P80 EDC build. And it was time to go home at that point.

Today I had a combination of tasks. I added an optic. So I needed to get that zeroed. I also wanted to continue reliability testing with both FMJ and HP ammo. The weight of an optic on the slide can potentially cause issues.

The optic zeroing and testing went very well.

I got some new 124-gr FMJ ammo to try, and it proved to be reliable with the optic installed.

I had also recently purchased some Federal HST 124-gr hollow points to test in addition to my existing stash of HST +P 147-gr. I ran 25 rounds of the new HST 124-gr ammo through with zero malfunctions. I forgot to bring a box of the HST +P 147-gr ammo. But then I remembered I had some in my pocket, in my spare mag for my current EDC - a Gen 2 Factory Glock 19. I popped the spare mag in my P80 EDC build and fired 9 rounds. Zero problems. I decided that was enough for now, and I didn't want to "waste" the rest of the ammo in that mag. I dropped the mag and went to manually eject the live round in the chamber.

Rut-roh! The slide wouldn't rack! It was stuck! I mean it would not BUDGE... at all. It felt like it was glued shut! Surely my eyes and hands deceive me. This can't be happening with my "perfect build!" I kept the muzzle pointed down range and tried to rack the slide again. No dice! REALLY?!?? WTF?!?? Tried AGAIN with some real force. NOPE! I'm pretty sure I heard my gun laughing at me!

Naturally, we test defensive ammo compatibility by loading and FIRING it. Usually all of it - whatever we loaded in the magazine. Checking accuracy - POA = POI. Checking reliability in terms of feed, fire, extraction / ejection. We don't want to find out the ammo causes problems when the SHTF. One of the most common issues with Hollow Point ammo is Failure To Feed (FTF). The truncated shape of hollow points may not play well with the barrel feed ramp in some cases.

But, what about manually cycling live rounds without firing them? Manually extracting live rounds? We do it with Snap-Caps during function testing at home. But, I will admit it had not occurred to me to test it with live ammo. But by chance at the range, I tried... and failed.

Finally, I decided to just fire that stuck round (without the mag) and see what happens. Bang and a perfect extraction and ejection of the spent shell. What gives??? It occurred to me that perhaps the 147-gr bullet in the HST +P round is slightly longer, and maybe that's why it was stuck when I tried to manually eject the live round. Time to go home and do some analysis!

I went home. I loaded a mag of regular HST 124-gr ammo and manually cycled it. Like buttah! No problems. I loaded some HST +P 147-gr ammo. Chambered the first round. It fed without a problem. Then I tried to eject it. Problem! Jammed again. I tried again with more force. Jammed!! I tried again using MORE force. Success! It took a surprising amount of force to get the round to eject. What is up with that?? No bueno!

Time for more analysis. "Plunk" test time! The Plunk Test involves removing the barrel and dropping a live round into the chamber. It should drop in easily. You should be able to rotate / spin the round in the chamber easily. And when you turn the barrel chamber-down, the round should drop out.

I compared CCI FMJ 124-gr, Federal HST 124-gr, and problematic Federal HST +P 147-gr. The CCI FMJ and HST 124-gr passed the plunk test easily. However, the HST +P 147-gr.... was what I will call "sticky." If I pressed the round into the chamber, I could turn the barrel upside down and the round would stay in the chamber. Interesting.

Next... Let's get out the digital calipers. I measured the same three rounds - CCI FMJ vs HST 124-gr vs HST +P 147-gr. I made this infographic to demonstrate the differences in length and shape between the three rounds:
View attachment 6373
While the HST +P 147-gr is longer than the HST 124-gr, I realized that it couldn't just be the length causing the issue. The CCI FMJ 124-gr ammo was longer than both of them. But, look at the bullet profiles. The FMJ is nearly conical, as is most 9-mm FMJ ammo. The HST 124-gr ammo is fairly tapered, as well. But, you can see that the HST +P 147-gr has a side profile that is straighter... more parallel... not as tapered. Perhaps this is causing the problem with manually cycling / extraction of the live rounds.

The take home message....
Test your defensive carry ammo! Whether your EDC or Home Defense gun is a factory firearm or a PMF (personally made firearm).

Test it in every way. When I previously tested the HP ammo, I fired every round I loaded in the magazine. It was "by chance" today that I decided to stop halfway through a mag and unload the gun. That's how I discovered the issue with the HST +P 147-gr round.

What say you? Comment below!
I have absolutely tested it. and both my p80 g17 builds really, really like the Speer Gold Dot 124 grain +P stuff. A LOT.
 
I heard back from Zaffiri:

Thank you for all the information. I have spoken to our barrel production manager, and he is going to dive into this issue. The main problem is that our barrels are made to SAAMI spec which is a standard spec that most companies use for chambers. We are going to do a batch testing to see if some were just out of spec or if the design needs to be changed from SAAMI spec to accommodate those different types of ammo. We are looking into the matter to find a solution or update information on the website. I will update you once we have some more information. Again, thank you for bringing this to light.

Team @ZP

Coming up on 2 months... haven't heard back, yet. 😐
 
Coming up on 2 months... haven't heard back, yet. 😐
Absolutely you have a barrel that the chamber is bored incorrectly
For the record, I also believe in and carry the GD, but 180grn .40, as well as the Underwood 200 grn hard cast in the woods.

I have to wonder if the aftermarket is just inherently sloppy, or if they simply don't worry about many things - like your defensive ammo cycling - since the overwhelming majority of aftermarket is not specifically focused for we who actually carry "built" firearms for protection, but for range game guns that will predominantly run FMJ, and the greatest risk is poor scoring should the product fail.

I'm definitely no machinist, but as @CECannonJr says - you're taking a couple 0.001". The same shit that creates problems with aftermarket slides, trigger bars, etc.

/K
 
Yet it passes the Go Gauge test.
I think what you're seeing is the Go-gauge is showing the CASE chambers appropriately, as the round is indexed on the case mouth. Incorrectly bored chamber can allow the FMJ bullet with the rapid taper, but the rapid taper of the bore interferes with the larger 147grn bullet. Could be inadequate bore depth, or improper bore taper, but this headache sure seems as a bore issue.

Seems as so many are running back to the 115 grn or 124 grn since the FBI has changed their mantra, that's quite possibly what the barrel manufacturer is catering to.

Of course, my universal solution is to seat a G23 upper and grab you a handful!

/K
 
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