I am fully aware of the wiki and the size differences, I have both at my home.
Can you please explain the stepped cylinder then with a .442 bullet heeled bullet and a bore that is .429? 13 thou compression before exiting the cylinder then 13 thou bump out to just engage the rifling seems insane.
The bore was slugged, a soft lead .430 bullet fits is perfectly and passed through the cylinder step easily.
This is not a British gun, this is an American gun.
As I said earlier - 44 webley is all over the place with heeled and non-heeled versions, which are the inside and outside lubricated versions you are talking about. If the bore and throat are .430" then just load a light .44 (.430") lead bullet or shot projectile to a case length and OAL that fits your and go for it. Should be fairly straight forward and you shouldn't need a bottleneck.
Lots of .430" lead bullets around but most of them might be heavier than you need.
Why did Iver Johnson put a short step in a long cylinder? These were not especially strong actions as you already noted. Maybe they were purposely limiting the power of the cartridge because longer cartridges had caused problems. Or maybe it was another reason entirely, who knows. A friend has a revolver much like yours but the bore in his is .425". IJ maybe wasn't top of the line in quality control.
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