Whether the expander was the OP's primary issue or not, I have a general disdain for expanding bottle-neck cartridge cases by dragging the expander button in the sizing die out of the neck as part of the case sizing process. I have found it difficult to adequately lube the inside of case mouths to eliminate the excessive friction without leaving so much gunk in the case mouth that powder granules stick during the charging operation (this is worse with flake and ball powders). For this reason, I have almost exclusively gone to a 3-step process by using a dedicated neck expander die for my bottle-neck cartridge cases like is done with straight-wall cartridge cases. Not only does this "push" the expander button into the case, but it also allows me to expand only the portion of the neck needed based on the particular bullet I shoot. In my 30-06, one of the loads I have developed is with a 125 gr. bullet which engages only a small portion of the neck. So, why stretch the entire neck when only the outer portion needs to be expanded. To each his own, but that's the insanity method I use.