In this final episode (thank God!) I tested Kaido's custom 255-grain conical bullets
http://www.youtube.com/watch?v=IkcvwP342Lg[/quote]
I suspect that a pure lead bullet would have loaded more uniformly and allowed more careful compression of the powder.
This has been my experience with trying to shoot hard bullets from C&B revolvers in the past. The "breakover" when the hard bullet finally shears in causes inconsistent compression.
The 255 would make an excellent bear load where penetration is the key with a handgun. Some friends are making 45 colts with long barrels (10-12") to use as "pocket rifle" bear guns in YNP. It will allow having a gun under a coat that is not visible to the tourons.
A tube over the loading lever as a "cheater" to give a longer lever helps too, easier to control.
Dan