The following is what I sent to a shooter in response to his request for information on my 2-D PPB that I designed for MY .40-65. That design is proving to be very easy to get to shoot well in all the rifles I've seen it used in, including a .45 caliber version in a friend's .45-90 C. Sharps. His rifle is not my rifle and I attempted to walk him thru the process I use to design these bullets. Since I know there are others who are interested I thought I might answer those questions in a single effort by posting it here. I know I can never repeat this enough, but I am trying. I never really know how well I explain this to others especially in writing. I am, at least at time verbally challenged and even more so when writing. In my own mine it is perfectly clear what I am saying, to others, not so much.
So here is what I wrote:
You probably have a standard Shiloh grease groove chamber in you .40-70 SS. Shiloh puts good tight grease groove chambers in all their rifles that I know of. These chambers do very well with PPB and the correct 2-D PPB should shoot with very good accuracy in your rifle assuming the above is true.
They don't put any real freebore in their chambers and that helps a bunch when shooting PPB.
I have to assume some things to give you an idea of how a 2-D PPB should be designed to fit your rifle. The more information you can give me the better I can help. I do not know your level of experience either so I will try to give as much good detail as I can, please don't be offended if you know all or some of this already.
If you have a standard Shiloh GG chamber then the base should probably be about .200" long and .409" in diameter after patching. The bore diameter should be .399" to .400" after patching. The ogive on my bullet is fairly short, only .530" long. If you have a 1 in 16 twist and you should stay with a 1.325" OAL for that twist. This is what we have so far .530 + .200 = .730". Then you take the 1.325 - .730 = .595 which is the length of the bore diameter section.
Your patches would be cut to about .900 high and the correct length for your base diameter with two wraps of your paper, approximately 2.5" + or - a bit depending on your paper and how you wrap (wet or dry).
The bore and base diameters would depend on your paper. If you were to use Seth Cole 55W it would add about .005-.006" to your as cast diameter, lets say .005 to keep it simple.
.409 - .005 = .404" for the base diameter as cast and .400 - .005 = .395" for the bore diameter, as cast. These diameters are important, too loose and accuracy suffers, too tight and they are hard to impossible to chamber. The lengths are a little less important.
One down side to 2-D PPB is they are complicated to size after casting, especially the bore diameter section. The base diameter can be size either before or after wrapping. It is critical to get the mold to cast to the correct diameters. You'll need a mold maker who can do this, there are several.
Again, so much depends on YOUR chamber and YOUR paper that I can not say with any certainty exactly what would work best for you in your rifle. What I just laid out here should give you an idea of how to figure that yourself, or at least how I figure this stuff. If you need more or better info then you'll have to provide more info on your rifle. It is still somewhat of a guess to design a custom fit bullet without having the rifle in hand.
I hope this info helps. If you have more questions please ask, I will try to answer them.
This may help with my explanation.