Did you trim the cases before or after you reformed them?
I actually trim the casing twice.
First I chopped 1/4" or so off the 06 neck with hacksaw. Trimmed the mouth briefly to remove burrs for subsequent steps.
When all steps were done; forming, neck turning, I trimmed to final length, and then annealed.
Did you anneal cases at any point? If yes, what was used to anneal them?
The last step is annealing in this case. Only for conversion that needs drastic working on the brass will I anneal before and after forming. 06 to 8mm is not one.
I anneal with propane torch and my fingers. No fancy crayon or due.
Did you reform the cases with or without the expander die?
Negative. Just the expander ball in the sizing die. It could be a bit tough to pull the expander out of the new neck because of the thicker wall. The dubious Lee collet doesn't help. You really need to cinch it down, or the expander will come off. Adequate of good lube helps. If there is still problem, pm me.
Were any cases you reformed originally in calibers smaller than .30-06 (.270, .25-06, etc.,), and did reforming them present any special problems?
I did 06 to 7.7 jap, 06 to 8mm, 0.38 spl to 41 long colt, and am going to try 6.5 carcano to 7.62x45 Czech. The biggest problem I have met so far is the new neck wall being too thick. Brass from the shoulder is extruded into the new neck to form the dreaded "donut". It could become a real problem, worse than dragging the expander ball, and needs to be removed. Inside reamer is the proper way. Outside turner works too, but requires extra steps.
-TL