One of my favorite cartridges, historic and versatile. I've only ever used modern Starline or W-W brass, and I don't load hot, so in my experience the only weak part about the brass is the neck. The neck is thinner than some other brass. this is one of it'd advantages, the neck will seal the chamber even at low pressure. IOW the crud and junk from the exploding black powder won't enter the action of the rifle. The 44-40 was a rifle cartridge, and handguns were made for it, but it was a rifle cartridge. In it's original chamberings, the '73 Winchester, it was loaded with black powder. The original balloon case held 40 grains of black powder, and the 200 gr lead bullet had a muzzle velocity of 1300 fps.
Therefore, everything below that is technically a light load. This, 200 gr load @ 1300fps, can be duplicated with 10 gr of Unique and a 200 gr cast bullet. The pressure is a bit higher than the black powder loading and in a '73, I would not use 10 grains. I used around 9.5 grains in a Winchester 1894 Commemorative, a Rossi 92 and an original 1892 SRC. My game is target and Cowboy Action, so I never handloaded beyond that.
The road to a higher powered 44 caliber handgun could have followed the the 44-40 path were it not for the thin cylinders of the SAA Colt. Elmer utilized the thicker cylinders of the 44 Special and as they say, the rest is history.
With the availability of new and strong lever guns in 44 Magnum, I don't see any use or need to rebarrel an old original 1892 to 44 Magnum, nor do I think one should load up the 44-40 to try and equal the 44 Magnum. Both the 44-40 and the 45 Colt can be loaded up to near 44 magnum performance, but I don't think you need to, or should.
What we as shooters should be doing is going after SAAMI and the gun makers to have 44 Magnum rifles chambered and rifled to handgun specs, and not to some slow twist overbored Marlin spec.
Back on topic, I have some of the older Lyman books, they loaded the 44-40 to some impressive levels. Lyman 40 lists 26 grains of 2400 and a 429434 gas checked 221 gr bullet for 1850 fps. That is listed in their rifle data, I don't think a SAA would stay together at that loading. That is not a pussy load, you'd be hard pressed to load a 44 Mag to that velocity. BTW: I've used the 429434 bullet in my 44 mags, and it shoots pretty good. It matches the shape of most 240 gr jacketed flat nosed bullets, a coincidence, I think not.
Nitro