What is the 25 SAW?

 

  The 25 SAW is a short action, non-magnum rifle cartridge based on our 7mm SAW case geometry but necked down to use .257 caliber bullets. It has a maximum cartridge overall length (COAL) of 2.960”, and an H2O case capacity of 54.2gr to overflow. That’s about 5% more case volume than the 25 Creedmoor. What does that mean for real world performance? The biggest advantage comes from the ability to use a wider band of available powders. The SAW case will produce a velocity increase over the Creedmoor of around 50-75FPS, and it allows slower burning/higher load density powders to be used without running out of room. For competition use where a minimum velocity must be met, this means that the 25 SAW can hit required velocities while running at lower chamber pressures, thus increasing usable barrel life. For dual use rifles that may be used in both competition and hunting, this means that minimum velocities can be met with shorter barrel lengths, increasing the versatility of the rifle especially when shooting suppressed.

 

A brief history lesson

 

  A little over 5 years ago, we did the initial development work of taking our already highly successful 7mm SAW cartridge and necking it down to .257 caliber. Thus the 25 SAW was born, at the time to take full advantage of the 131gr Blackjack ACE bullet design that had just made its presence known (you can read more about that initial development here). The new design showed great promise, but our development time with it was severely limited through the COVID years, starting Caprock Rifle Club, and a major expansion and relocation of the WTO shop.

  Fast forward to late 2023/early 2024, and the time we needed to really prove the 25 SAW out began to finally materialize. The high BC .257 caliber bullet revolution was also now in full swing, with multiple options available from both Berger and Hornady, the two powerhouses of projectile production for PRS/NRL Hunter competition shooting. With a full suite of highly efficient, highly accurate bullets that were purpose built for LR shooting available, the second cartridge in the SAW family now had room to grow.

Match Performance

 

  The first actual competition use of the 25 SAW was the 2024 Ghost Hunter, held on the Gunsite training facility near Paulden, Arizona. I wanted to test this cartridge in real world conditions and see if the consistency of the newcomer would match what we’d seen over literally tens of thousands of rounds through the 7mm SAW parent. I picked a starting charge weight of 41.6grs H4350 with a 135gr Berger Long Range Hybrid Target bullet seated over the top, and that concluded load development. The first three rounds fired stacked into a sub ¼” group, and the load showed minimal vertical dispersion as I moved out to 550 and then 970 yards. Muzzle velocity registered 2851FPS, more than enough to satisfy the NRL Hunter Power Factor requirements. Power Factor is defined as bullet weight multiplied by muzzle velocity, and the minimum PF number allowed is 380,000. With the 135gr Berger, the minimum muzzle velocity needed to achieve Power Factor would be 2815FPS.

  WTO Office Manager Sloan Kail and I shot the Ghost Hunter match as our first ever team event, and found it to be one of the most challenging NRL Hunter matches on the schedule. We managed to secure a top ten finish in the Team division and walked away with tons of good lessons that we’ve since put into practice. Regarding the performance of the 25 SAW, I found it to be very consistent and very accurate, although I don’t think I had full confidence in it simply because of my limited practice time prior to the event.

  I went back to my 7mm SAW for Open Light division and finished out the 2024 NRL Hunter season, but continued to practice and test the 25 throughout the year. During this testing, I played with several other powders and found great accuracy across a wide burn rate spectrum, finally settling on 44.0grs of Vihtavuori N160 as my final match load for the current barrel. This combo produces a very consistent, temperature stable muzzle velocity of just over 2900FPS and bughole accuracy. Now with more time behind the cartridge and very high confidence level, Sloan and I started the 2025 season in Wortham, Texas at the Freestone Hunter presented by IWI. This was an exciting match in a great new venue (a championship level motorcross track), and this time we walked away with the Team Division win! The 25 SAW really proved itself here, and I managed to only drop one shot with it across the entire course. Shooting suppressed with a 15lb rifle, recoil was incredibly mild and I frequently could watch my bullet trace to the target even from tripod and other modified shooting positions.

 

 

25 SAW Sample Load Data

DISCLAIMER: The following load data is to be used for reference only. This data was developed for our test barrels and is in no way guaranteed safe in your rifle. Always do your own research and measurements on your rifle, start low and work up carefully!

 

Max COAL’s

These are approximate and will vary based on sample bullet geometry.

 

133 Berger Elite Hunter: 2.940”

135 Berger LRHT: 2.942”

134 Hornady ELD-M: 2.930”

138 Hornady A-Tip: 3.000”

131 Sierra MatchKing HPBT: 2.965”

Lightweight Hunting Bullets

While our focus has been heavy for caliber bullets for long range competition, this cartridge can be very well suited to traditional hunting on game from varmints to mule deer. These measurements are included for those who might have that application in mind.

115 Berger VLD: 2.804”

110 Hornady ELD-X: 2.714”

90 Hornady CX: 2.825”

110 Nosler Accubond: 2.822”

85 Nosler Ballistic Tip: 2.811”

101 Barnes LRX: 2.786”

 

Selected 25 SAW loads

 

Unless noted, all velocity and group data were compiled from a 25” Rock Creek 1-7.25” twist M40 contour barrel, chambered with our standard .25 SAW .142” Freebore reamer. Chamber neck diameter is .292” which gives .002” clearance per side using formed WTO 7mm SAW brass.

 

133gr Berger Elite Hunter

• 42.6gr Reloder 16, 2.920” COAL, WTO Brass, CCI450 primer. 2990FPS/2.0SD. .5” at 100

• 46.8gr Reloder 26, 2.914” COAL, WTO brass, CCI450 primer. 2934FPS/7.2SD, .35” at 100yds. 22” Bartlein 7.25 5R barrel

135gr Berger LRHT

• 41.6gr H4350, 2.925” COAL, WTO brass, CCI450 Primer. 2851FPS/1.5SD. Consistent sub 1/2MOA load, 3” group at 970 yards. Max pressure found at 44.6gr

• 44.0gr N160, 2.925” COAL, WTO brass, CCI450 Primer. 2908FPS/4.8SD. Consistent sub 1/2MOA load. Max pressure found at 45.2grs, 3010FPS

134gr Hornady ELD-M

• 44.5gr N560, 2.925” COAL, New WTO brass, CCI450 Primer. 2914FPS/5.0SD. .448” at 100

• 42.0gr N160, 2.925” COAL, New WTO brass, CCI450 Primer. 2850FPS/2.6SD. .392” at 100

• 46.4gr N165, 2.925” COAL, New WTO brass, CCI450 Primer. 2899FPS/4.8SD. .474” at 100

• 43.2gr N555, 2.925” COAL, New WTO brass, CCI450 Primer. 2894FPS/8.3SD, .296” at 100

• 41.6gr H4350, 2.925” COAL, New WTO brass, CCI450 Primer. 2910FPS/6.7SD, .421” at 100

• 43.0gr Staball 6.5, 2.925” COAL, New WTO brass, CCI450 Primer, 2881FPS/1.4SD, 1.047” at 100. Poor accuracy in comparison to other options.

138 Hornady A-TIP

• 44.5gr N560, 2.955” COAL, New WTO brass, CCI 450 Primer. 2883FPS/3.8SD, .256” at 100

• 43.2gr N555, 2.955” COAL, New WTO brass, CCI 450 Primer. 2842FPS/5.4SD, .480” at 100

• 42.0gr N160, 2.955” COAL, New WTO brass, CCI 450 Primer. 2800FPS/6.2SD, .5” at 100

• 45.9gr N165, 2.955” COAL, New WTO brass, CCI 450 Primer. 2827FPS/5.0SD, .520” at 100

 

How to Feed it: Forming and preparing 25 SAW brass

 

 

  The first step in loading for the 25 SAW is to form cases to the proper dimensions, necking down existing 7mm SAW brass to .257 caliber. We have developed two forming methods that are equally successful.

Form Die method

 In this method, we use a custom cut 25 SAW form die (pictured above) to do the initial neck down. These are available for purchase from us when having your rifle chambered, and it is a very simple tool made by cutting a die blank with the actual 25 SAW chamber reamer. This does not size the body dimensions of the case at all, and only reduces the neck diameter down to final chamber size. After running through the form die, run your cases through your bushing sizer configured for 25 SAW. We configure these by using our standard Redding Type S 7mm SAW bushing sizer die, with a .25 caliber expander/decapping rod and a .281″ neck bushing. This sets optimal neck tension and you are now ready to load. There is no need to use the form die on subsequent firings; simply resize the cases as you would for any other cartridge.

 

Bushing Form method

 Brass can also be necked down from 7mm in two steps using a bushing sizer die and two neck bushings. To use this method, you’ll need a Redding 7mm SAW bushing sizer die configured with a 25 cal expander/decapping rod, a .292″ neck bushing, and a .281″ neck bushing for final sizing. First, install the .292 bushing in the die and run your brass through it for the first pass. Ensure that that your die is correctly installed in your reloading press so that the neck is sized, but the shoulder is not bumped back. After the initial step down, switch to your .281 bushing and run through again to set final neck tension. Because neck bushings do not size all the way to the shoulder, you’ll notice a slight bulge on your cases at the neck/shoulder junction when first sized. This does not alter case volume, and will disappear on the first firing of the brass.

 

Short Action Customs Dies are coming soon!!!!!!

  The exemplary SAC die sets for the SAW family of cartridges are currently in development, with bushings coming for 22 SAW, 25 SAW, and 7mm SAW. Look for these later in the summer. With the SAC die set, forming cases to 25 SAW dimensions will be a very simple process thanks to their bushing design. Just run the case through the sizer, then run it over the correctly sized neck mandrel and you are ready to load.

 

 

Is 25 SAW better than 7mm SAW?

  The answer to that depends on your application. For overall versatility, the 7mm SAW wins the day. The ability to shoot bullet weights from 95 up to 195 grains gives the parent cartridge the advantage here. The 7mm is right at home on the competition circuit, with multiple match wins in both Open Heavy and Open Light weight divisions of NRL Hunter competitions all over the country. And for a true dual use rifle capable of hunting up to elk sized game, the heavy .284 cal bullets are going to deliver more energy on target. However, the 25 SAW will deliver flatter trajectories and near identical wind drift out to 1000 yards as its bigger brother, with less felt recoil. See the charts below for a visual comparison. If you are chasing smaller game or going all out to build your next dedicated match rifle, then the quarter bore SAW deserves your full attention.

 

The charts below represent an apples-to-apples comparison using the same atmosphere of 26.65Hg station pressure and 50 degree temp. Velocities are pulled from actual test rifles with 24-25″ barrel lengths.