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The OAL length thing is simply not an issue - with 44-40 you have to crimp them, and the bullets have crimp grooves in the right place obviously. You crimp into the crimp groove.
If you decide to take up cast bullet making, then talk to me and there are a couple of bullet designs that are sold by Accurate Molds that are cpies of the original bullets, and with larger lube grooves, since modern black powder is not as good as the powder available in the 19th century, more lube is required to soften the fouling,
But since you rifle has a .430 size barrel load up either a 200 or 240 grain Hornady XTP - either will do - with 26 grains of AR2207. Crimp it hard with a Lee crimp die. Then go and shoot it for us and see how you get on.
Perfect, thanks for all the advice! I’ll be sure to let you know how I get on with it, just need to dedicate some time (and purchase some dies, primers, projectiles and powder)
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