Reloading for 44-40
I shoot several thousand 44-40's in Cowgoy Action through the course of a season. Here are some of my observations. Firstly, with regard to bullets, jacketed bullets (Win or Rem. 200 grn) are sized .425 - 426" and have a crimp groove so crimp them generously or they may push back into the case if used in any of the inline magazines especially when using light smokeless loads. Cast lead bullets of over .427" may not fit into chambers. They also should have a crimp groove. The old Lyman 42798 mould does not have a crimp groove but 427666 does.
Brass is very thin and easily damaged if bumped into the bottom of a die during the loading process so stop and look if something doesn't feel right. There are no carbide dies available for this calibre so cases must be lubed for the sizing process. So tumble the cases after firing.Keep the cases clean and brass life and die life will be extended. I have tried most of the various manufactures of dies and Redding,Lee and RCBS Cowboy dies in that order work the best. Believe it or not there has not been a SAMMI spec on 44-40 dimensions until just lately and older die sets and firearm chambers vary wildley, especially on shoulder dimensions. I have tried just about every method known crimping cases and a roll crimp is the best therefore one must trim to length at least once after 2nd or 3rd firing.
Moderate charges of Bullseye,Tight Group and the new Trail Boss seem to work best. Trail Boss is new and really has promise as the best but I have only done some pliminary work on it, so far I'm impressed. Triple Seven is nice stuff if you like smoke and boom but back off what Hogdon says to use as I got into trouble with my local Cowboy Range Master after blowing holes through his mild steel targets! The loads were safe but WOW! 22 grns under a 200 grn. lead bullet made HIM happy and accuracy improved.
That's my two cents worth, I hope it helps some.