I was finally able to bring this rifle out to range for first time over the holiday weeekend.  As I posted earlier in year, it is an original J.M. Ballard A-1 Mid-Range with a very near mint bore...chambered for what I had thought was a .40-70 Ballard..more on this later.  Brass was Betrum from Buffalo Arms Co.  Since I last posted, I picked up a Lyman 406150 S.C. mould.  Using 30-1 lead-tin, it drops a 330gr. round nose at .405" dia.  My bore slugs .404, with a groove dia. of .4094".  This bullet is a nice snug fit in bore when chambering.  Dropping 70grs. Swiss 1 1/2
FG & a .06" fibre wad I only seated a portion of bullets base band in case..just enought to ensure bullet straightness.  I also loaded some Brooks Postel 300 & 350gr. bullets of 20-1 alloy sized .409.  I loaded more of the Brooks because I was sure they would be the more accurate..being nearly groove dia.   Lube for all bullets was SPG.  I only have a 100yd. range and took some time picking out a front sight appature that gave good target definition.  First up was the Lyman 406150.  I was pushing 1 damp patch thru after each shot, drying chamber & leaving bore damp.  I was quite surprised when all 5 went into a 1 1/8" group.  I could hardly wait to try the larger Brooks..but the accuracy just wasn't there...while I might get two shots close..most groups were 3"+!  What gives?  It wasn't until cases were washed & dried and measurements taken I found the answer.  The case mouth had opened to a whopping .425"!  It seems my advertised .40-70 was in fact chambered for the heaver "everlasting" Ballard .40-63 case...something even a chamber cast wouldn't have detected.   Having had excellent service from Rocky Mtn. Ctg. Co. in past with a .25-25 Stevens, I will put in an order for the proper sized case.  And here is where I would like your help...I would like to shoot P.P. as well as G.G. bullets.  I have a Tom Ballard adj. P.P. mould & have come up with a bullet .4045" over patch.  This is a nice snug push thru bore.  I can also size G.G. to either .409 or .410 dia.  I am wondering for P.P...as well as that Lyman 406150 if I should specify a .405 I.D. and for G.G. a .409" I.D.  Or do you think I should go a bit larger for bullet expansion?  I do have reloading dies to size case..but would prefer not having to size at all.  I also plan on having a large pistol primer pocket cut instead of large rifle.  I will not be using smokeless in any form in this rifle.  What do you black powder experts think?

Hello, RSW.  While I cannot be absolutly certain the sights on gun came from the factory..the patina on both match the rest of rifle exactly.  Front is a Ballard windage adjustable..I couldn't find any original Ballard inserts so I had Distant Thunder make up a complete set of inserts including 2 sizes of pin head post & flat top post, as well as appatures.  The rear tang is a Ballard Mid-Range vernier.  Both sights are very tight and precise.  It seems we think alike.  I have two Tom Ballard adj. P.P. moulds with cup base.  One is a straight sided and the other is tapered.  In addition, I have a Fred Leeth adj. P.P. mould with a larger meplat with cup base as well.  The tapered ones patch up just as yours..with base nearly to groove dia.  I have been using a thin paper wad placed in primer pocket before priming for years..even in my .22 Hornet brass.  I have thought of breech seating..though I have always been curious just how acccurate these rifles could be with fixed..as they were originally shot at Creedmoor.  I made up a brass 36" drop tube & all charges are weighed using Swiss 1 1/2.  I might just try B.S...simplifies the ctg. case issue.  And of course bullet is fully supported.  I could probably spend the rest of my shooting life learning all the accuracy secrets of this rifle.  Thanks for reply.

RSW youv'e got me thinking now of B.S. P.P...Just wondering if you or anyone has tried the old Chase paper patch?  This would simplify patching..and insure patch seperation at muzzle.  There is mention of placing patch in B.S. & bottom edge of patch curls inward..this would insure bullet doesn't shoot thru patch..if that is even a concern with the quick obturation of black powder..but it sounds like seater has a radiused bottom edge in order to be able to curl paper?

When I was shooting P.P. in my Shillen barreled Borchardt .22 Hornet, I was vibratory tumbling patched bullets in Moly for 1/2 Hr.  Running them thru .226 sizer put a shiny hard finish on paper.