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44-40 Bullet Size Questions?

I have an 1866 Winchester (new) chambered for 44-40. The bullet diameter for a 44-40 is .427 but after measuring the barrel bore I find it to be .430 (Winchester may have done this to keep the pressure down on their brass receivers) The question I have, is can I use .44 caliber bullets which measure .429 to .430 diameter? .44 caliber bullets will provide a cost saving as well as better selection. I wish to use thicker Starline brass and flare the ends if required to start the bullets should they be a little tight when seating. Anyone with prior experience on this subject that wishes to pass along information would be appreciated, thank you.
 
You may very well find some cast bullets that are .431" if you look around. Dardas used to size them up to .433" I think but is no longer in business. If you use copper jacketed bullets, I think you will be fine. I have no experience with modern 44-40s, but it appears like they recognize that today's shooters will probably be using '44' bullets that are .429"

When you get into old 44/40s with groove diameters up into the .436" .437" area things get tricky.
 
The bullets we use are the .429 cast, we just use a good crimp not hard. The starline brass works fine but
you may find the case mouth still a little thin. Make sure you crimp in a extra step, you will have a lot
of problems if you try to seat and crimp with a single die.
 
It will all depend on your chamber. In my original ‘92, a 430 Hornady is stiff to chamber. A .427 bullet is fine. So my advice is to try some swaged/cast in .429 and see if they chamber.
 
If the lead used to make the bullets is soft enough the bullets will obturate to fill the bore. Case in point I shoot a .442 paper patched bullet in my 45-70 Sharps. The bullet expands to fill the bore with no loss of accuracy. Swaged bullet will probably shoot the best. Check with Buffalo Arms and see if they carry them..
 
If you know your bore is .430", you are half way there. You mentioned it was a new gun. I assume this means a new manufactured one? Call or email the manufacturer to see what the chamber is cut for. A lot of today's manufacturers have adopted current dimensions to cut down on confusion. Or you could just get a couple or so .430" bullets from a friend and load a couple of your cases to see if they fit and function. If they do you are good to go.
 
Cerrosafe is your friend. The case necks are thin which will help with larger diameter cast bullets. Easier to smash if stepped on however. I think there is an unwritten law about jacketed bullets in a cartridge made for the one true powder.
 
I have an 1866 Winchester (new) chambered for 44-40. The bullet diameter for a 44-40 is .427 but after measuring the barrel bore I find it to be .430 (Winchester may have done this to keep the pressure down on their brass receivers) The question I have, is can I use .44 caliber bullets which measure .429 to .430 diameter? .44 caliber bullets will provide a cost saving as well as better selection. I wish to use thicker Starline brass and flare the ends if required to start the bullets should they be a little tight when seating. Anyone with prior experience on this subject that wishes to pass along information would be appreciated, thank you.

Yes,

Use .428" to .431"

Soft lead will expand into the grooves even if using .427". If using hard lead, .429" is fine. Try many different ones until you find what works for you. It can be a long process but the 44-40 has great ballistics if one does his homework.

If loading for plinking, anything works. If loading for long distance accuracy, you may find it quite challenging until you use the correct combination.

Try this: https://sites.google.com/view/44winchester/handloading?authuser=0

This is my favorite for shooting out to 200 - 265 yards

200gr 43-214A, sized .428"
25.8gr Reloder 7
Starline brass
CCI 200 primers
1.600" AOL
1,361fps
<12,500 psi...SAAMI Max 11,000 psi (13,000 cup)

For use in my Uberti Winchester 73"
 

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I was planning on using jacketed bullets, but I feel the same applies for the correct barrel fit.

Different weights, different designs, diameters and different lengths can greatly affect chamber pressures. I have shot Winchester JSP .4255" bullets in my .429" bore with no ill affects. Accuracy is good pending powders and distances used.

Word of caution when using small diameter bullets. Use Lee resizing dies to fully resize the neck. Also, use a Redding Profile Crimp die. This is make for appropriate neck retention. This keeps the "undersized" bullet from telescoping down into the case from the magtube spring tension when used in rifles.

RCBS and other 44-40 dies are made to resize and crimp for larger diameter bullets, not allowing for proper neck retention with the Winchester and Remington 44-40 JSP bullets.

Here is some more information with photographs: https://sites.google.com/view/44winchester/handloading/redding-profile-crimp-die?authuser=0
 

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Yes,

Use .428" to .431"

Soft lead will expand into the grooves even if using .427". If using hard lead, .429" is fine. Try many different ones until you find what works for you. It can be a long process but the 44-40 has great ballistics if one does his homework.

If loading for plinking, anything works. If loading for long distance accuracy, you may find it quite challenging until you use the correct combination.

Try this: https://sites.google.com/view/44winchester/handloading?authuser=0

This is my favorite for shooting out to 200 - 265 yards

200gr 43-214A, sized .428"
25.8gr Reloder 7
Starline brass
CCI 200 primers
1.600" AOL
1,361fps
<12,500 psi...SAAMI Max 11,000 psi (13,000 cup)

For use in my Uberti Winchester 73"
You are one clever Dude. Thanks so much for the info.
 
I have an 1866 Winchester (new) chambered for 44-40. The bullet diameter for a 44-40 is .427 but after measuring the barrel bore I find it to be .430 (Winchester may have done this to keep the pressure down on their brass receivers) The question I have, is can I use .44 caliber bullets which measure .429 to .430 diameter? .44 caliber bullets will provide a cost saving as well as better selection. I wish to use thicker Starline brass and flare the ends if required to start the bullets should they be a little tight when seating. Anyone with prior experience on this subject that wishes to pass along information would be appreciated, thank you.
yes, I use .429 cast bullets in my rifle & sixshooters. .430 jacket bullets would work also.
 

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