JWL wrote on Sep 19^th, 2017 at 2:53pm:


Couple things I'd recommend to do. Yes, you can use too much lube, and it will create dents in the cases. I prefer the spray lubes like Hornaday sells, as they lube well, but don't leave build up that creates dents.
I also would make sure you don't take too large a step doing the forming, and make it in at least 3 steps. Also don't take each step all the way down in one pull, unless it sizes down with an easy pull. 
I have made .33 Win from .45-70 by running them into .40-65 dies first, then .38-56, and finally .33 Win. and it worked great. 
I'd also trim some excess length off first, so you're not sizing brass you'll cut off later. Just rough cut them close, and final trim later.
I'd try not to anneal them too much, or maybe not all until I tried the first one. You'll be able to tell how it goes, and then know if they need annealing. I didn't need to when I went from .45-70 to .33 Win.

Stop using the thick lube! There's no way to avoid the sizing marks, if you continue with that lube. 
When you say you're doing 5-6 passes, do you mean with one die, and not gradually forming down with different dies? Tough to do this big a jump with just one die and go straight from .45-90 to .38-70!
Putting them through the .40-65 die will help, but even that might need 2-3 staged passes to get to .40-65.
You might also have to ream case necks once you get them down to .38-70, as they may be too thick.

I tried a few with just the neck and a few about 3/4 of the way down.

Only anneal as far down as the neck goes, keep the rest of the case in water to keep the bases from becoming soft. Use Imperial sizing die wax sparingly. Just tap you finger in it and spread it evenly over the case. Don’t slather it on; a little bit goes a long way. If your doing it right one can of Imperial should last you a lifetime and you can pass the rest down to your son.

40 Rod

Thanks to everyone for the helpful info