Jhon, the nick in the case mouth is caused by your extractor. Which will be strong enough to make that as the case gets drawn out and the mouth of the case gets drawn free of the chamber, it gets that nick in the thin brass. You might look at weakening the extractor spring a touch, which will stop that. Otherwise, just extract slowly and hold the case down until its pulled back far enough you can handle it out.
Reloader 7 will make the same bulk smokeless load as AR2207 / H4198 with 26 grains. And both give excellent velocity (and pressures good for '73 rifles.)
My .44-40 is now the cheapest rifle to feed - brass lasts a long time, with 9 grains of AP70N per shell, powder is ridiculously cheap, and I make my lead bullets. I am paying for primers really. Now that I can make a crimp under the bullet to hold my projectiles in place over smaller smokeless loads with the pipe cutter, the last bulwark was overcome.
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