Froggie.....I've never tried the 405 Winchester brass, thought it might be too short and by hook or crook I have managed to get a decent supply of 40-85 brass so didn't have the need.
My bore slugs out at .408" but unless everything is just perfect, I can't get a .408" diameter bullet to chamber even with the thinner brass mentioned. I usually take the newer mold bullets and run them through an old Ideal hand sizing tool that brings them down to .406" diameter and then I'm good. I use really soft lead, so it bumps up. Lately I've been using mostly paper patch so don't have to worry.
I use a standard 2-15/16" case and have no problems there. I did a chamber cast quite awhile ago and it confirmed the .408" groove. Sent it to Dave at RMC when I had my cases made.
When I bought this thing, I dug deep and bought a RCBS full length die set. Don't use them much to load, but the full length sizer has come in handy a couple of times. I use the old tong tools to load, either Winchester or Ideal. If you have some cases that need sizing, be happy to run them through the die for you. I'm pretty sure it's not worn out yet.
I take it yours is a #5 also......would love to see a picture. These old boomers carry a bit too much black powder in a 40 caliber to be target rifles, but they were made for hunting and do that well.
max