Using the things I had on hand to work with I started taking soft lead castings from pistol molds, sizing the hind ends to slip into the chambers so that alignment was achieved and the front part of the bullets sheared off the same as round ball. That was in the late 70's shooting a Navy Arms 1861. Later on I applied the technique to .44's and eventually to a reproduction 1858 that was reworked specifically to use .41 caliber revolver molds. Tailoring the bullets to suit a particular piece is one way to skin the cat but I'm working on the "better mouse trap".
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If there's anything that's been hinky about Pietta .44's it's having .446" chambers. Lots of people modify the cylinders to increase the diameter on the chambers to be something closer to their barrels. So, OK, what if the reaming didn't extend all the way to the bottom and I could just stick castings into the chambers instead of oh so carefully crafting each bullet. Not saying there's anything sacred about the numbers included in the sketch above. Maybe the front of the chambers should be around .450", just so as the bullets were in between that and the "A" diameter. I'm thinking the bullets would seat against the powder charge and the taper. And, that the displaced lead would squish out to the larger diameter back there immediately ahead of the taper.
So I was patting myself on the back and hit a snag right away. Pietta changed the style of their rifling. Instead of having traditional percussion revolver rifling they went to modern style with narrow lands which turns their barrels into mostly .45 instead of mostly .44. Now I don't know about how much metal I'm comfortable with removing from their cylinder walls to make their chambers match their barrels.
Once upon a time it looked as though just replacing their barrels made more sense. Now that they monkeyed with the rifling geometry I've come full circle.
Any how, if you have old style rifling instead of new, making the hind ends of the bullets slip into the chambers still oughta solve the problem of obtaining good alignment during loading.
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