40 70 PP problem

[ken s]

I'm shooting an original 40 70 SS. .403. bore
I'm paper patching a custom 330 and 390 , both custom moulds.
I'm having trouble with getting the patched bullets in the case.
too tight and patches are ripping. some go in, some don't.

I'm patching with .005 onion skin, to .403...but it comes out larger.
I have a .409 expander, but if I go out all the way to 409 the case gets distorted. and won't chamber. it goes too far in the case. full length sizing is then needed.
I've ordered a .410 to 413. Hoping the start at 410 will expand it just enough without going too far in the case.
I use the factory crimp die to tighten around the bullet.

AND. in PP casting...is PURE LEAD BETTER THAN 1 20. IT SEEMS THE ORIGINALS WERE PURE LEAD....

Any thoughts?