RCBS and Lee don't have dies...

[Andy]

What is the required outside diameter?

Drill a hole through a piece of steel plate, smooth it, lube it, and pull it down over the empty shell casing for the length requiring sizing (i.e. neck size it).

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[Stevo]

I hope you don't need to crimp it, too.

[buffdog]

Be Very Careful If You Apply Heat On It.....Aluminum Melts Very Easily.

Also, you mentioned that you wanted to use it for a door stop. If you do that, you better get everyone in the family a pair of safety boots. That sucker is going to be Top Heavy, and will fall over easily unless securely anchored down.

I like the idea of a wooden projectile. The Navy used them for practrice gun drills, and it would be a lot lighter. You could even pour a bit of lead or other weight into the bottom of the case, but do not fill it.