I think I'm gonna order this chicken bullet I modified off the Sagebrush site for the 35-40.   

This is for a relined Marlin Ballard with a .357 hammer forged liner;   Groove=.357 Bore=.348.     I’d be interested in comments on this drawing concerning fit or whatever you might add.   The chamber is a done deal but bullet fit is something I’d be interested in from those more experienced with Black Powder than I am (which will be just about anybody).  I'll try and add a pdf of the chamber in the next post.

As it stand now, I drew the bands so that I could seat the bullet all the way into the .500 neck covering the lube groove above the last full .359 band and exposing the two .348 bands, which would be seated out into the .348 diameter rifling.   Plus or minus tolerance would be positive for the full size driving bands and negative for the reduced driving bands.  While it’s not a bore rider, the front driving bands sort of function as such.  The way I drew the chamber/reamer, my fireformed brass allows for finger-seating a bullet sized to .359, having only to bell the neck.  I am in hopes that this will optimize concentricity.

I’m curious about fouling being an issue in cases where that fit is exact or if it should be further reduced to allow for fowling.   So far most of my BP shooting has employed blow-tubing as opposed to wiping.    I may have to wipe as opposed to blow-tubing if the fit is tight but some of that would depend on the mold maker’s tolerance.

btw, I'm gonna give take a chance and order from a new source: (You need to Login or Register to view media files and links) The drawing I just created says Brooks but that is just because I didn't know how to add a new mold maker to the drop-down box.   From his web site, he's a shooter and has good reviews.  I've been wanting to try him out so I know if he's an option for other molds.

Good looking bullet John, tell me how it shoots and casts, I might want to try that for my chicken bullet./-

Just a personal opinion but before the bullet leaves the barrel the base will try to catch up to the nose and thus making the bullet shorter in overall length before it leaves the muzzle than originaly cast. With that being said one only wants enough lube grooves as not to create a leading issue. When the base trys to catch up to the nose and is referred to as the accordian affect and the lesser amount of lube grooves required to prevent leading the better and the less effect the accordian effect will have. So one does not want to enhance it by having more lube grooves than is actually required to achieve the best in accuracy.

JLouis

John I'm not sure how much Black powder J Lewis shoots but I shoot a lot and just from my personal opinion your bullet looks good. I have a .40 caliber Kidwell bullet that is a lot like yours and it shoots to 600 yards fine , plus I have a fellow shooter who shoots a sagebrush made for a 10 twist that has more lube grooves than yours and I know it shoots great. That's why they call them mini lube groove bullets so they don't distort.

Thanks Hiwall.    I know Steve Baldwin recommended the version I modified.   He also shoots the heavier one I mentioned.    

I was using 40gr of OE 1&1/2 in what I've shot so far (the Lyman).   That gave me 1267fps velocity and a good lube star.    I'd hope to get that much powder and more if possible for just a little more velocity considering the 14 twist.

I note on your reamer drawing, the useable case will only be 2.075 long. Is that right? Also, your pilot is larger than your bore. Everything else, looks ok.

I don't think that the grooves should be more than .015 deep, so that the miner diameter would be .329, instead of .314, it makes for a stronger bullet. My drawing of the PJ Money bullets, also have that groove depth. 

I would also in crease the first two bands, behind the .348 band, to .350 & .352, to better fit the leade of your chamber.

Frank

Just a thought, you might look at an elliptical nose with a 
.17" hemi meplat for better yet BC.
beltfed/arnie

John if 45HiWall says it works the way it is I would not change it based on his experience.

JLouis