Forming Cases and other things

[Nuclearcricket]

In the not too distant past I have been involved in some discussion on what can be formed from what cases. I tend to be a bit stubborn at times and not just take others word for things if there is another way I can find out for my self. Now I have a project in the works to build a 44-60 bottle neck and BACO brass is expensive, and being formed from 348 cases, its quite thick. Another round that was discussed with the 44-77. Some say it could be made from 45-90 and others said no way. I had to find out for sure to satisfy my curiosity.
I spend some time with prints, and some loaded ammunition and precision measuring tools. The difference in diameters on various cases wasn't as much as I thought. The 348 case is larger and would have to at least have the web area turned down, guess that is why the BACO cases are so expensive. I just didn't' know that till I got a hold of a round and made some measurements. I don't have any 45-90 cases but figured the 45-70 would be pretty close, and at least close enough to experiment a little with. It only needed to expand about .015" or so to fill out the shoulder and the body areas. Having never done any case forming I was a little nervous but figured I could try one case and see what happened.
The only issue I could see as being a problem is that my 44-77 is chambered for cases with an .080 thick rim, a bit thicker than the 45 cases. Solution was to set up and just neck size till the case would just chamber and fire a primer. I got lucky on the first pass. My next concern was the case being .150" short for the neck. OH well, wuoldn't be the first time I have had to mine lead.
I loaded up a round in a Nickle Remington once fired case with the bullet set out where they normally are for the 77 case. The case only held about 67gr of FFg Goex, that just is what was setting on the bench. Off to the range we go. I had a few other rounds to burn up and fired the 45 case last. Noticeably less recoil. I had been wipeing the bore between shots, so a few wet patches and a patch wet with Borezilla and off to home we go.
Today a dry patch, 2 passes wiht a nylon brush and a dry patch and in goes the bore scope. No lead that I could see. I was happy. The case expanded nicely in the body and shoulder area. The base (web) area is still undersized but shouldn't be a problem. Case volume is about 10 or so grains less than the Jameson brass I have.
Bottom line, it seems the conversion is doable. It may require a different extractor depending on how yours is cut and what rifle you are using. Other than that, it seems to be a workable way to get a 44-77 up and running.
My next step will be to maybe fire this case one more time and then shorten it to 1 7/8 and neck it down and see what the capacity is compared to the BACO 44-60 case I have. I am hoping it hold a bit more powder, someplace in the 50 to 55gr range. Sure will beat the heck out of paying what BACO charges for the 44-60 converted cases.
As a bit of a side note on the 44-60, I have actually met a shooter that has one. Its a roller built by Dave Higenbothem (sp). He told me that Dave felt it was an excellent cartridge and made the owner an offer, if he didn't like it, Dave would re-barrel it in any caliber he wanted. Over on ASSRA web site they recently published a list of Dave's rifles by SN, cal and configuration, there are 2 44-60's on the list.
Sam