Recently acquired one of those myself, and in my reading/research found that they originally used a 330 grain bullet (or sometimes a 300 grainer).  I bought a mold from Accurate -#41-326 tapered - and tweaked the bands a bit to match my chamber cast. Nice round holes at 200 yards and no leading.  I can't help with black powder loads, I was using 4227.

Regards, Joe

Thank you Marlinguy and Jfeldman. That's what I was looking for, and no matter the powder issue. Black powder just has to fill the case (with room for a seated bullet of course) and you experiment from there: wads, primers, bullet designs, etc. I also occasionally use the experimental propellants as well . Thanks again.

I was wondering what you guys use for brass. A friend of mine just bought a Pacific in 40-63 and he asked me what to use. I know the 444 Marlin is the correct base diameter but is too short and the rim isn't correct. The 405 is about .010" or so small at the base but I guess it is OK after fire forming.

Deadeye,
The 40-63 Ballard is virtually the same cartridge as the 40-70 Ballard, but it’s chambered for Everlasting brass which is just a tad thicker. I know Rocky Mountain Cartridge LLC in Worland, Wyoming offers it, and you might find 40-63 at Buffalo Arms, Sandpoint, Idaho, but BACO’s is not Everlasting. RMC brass is, and it’s pricey. I use it exclusively. It will outlast me and my kids. The 40-63 is primarily a black powder cartridge in older Ballard’s, etc. but with caution and common sense you can use smokeless. Just don’t do it in an old rifle with a cast receiver.

Correct me, if I'm wrong but, I think the 40/70 has a larger diameter neck, to shoot GG bullets?

I do know that you have to neck turn the 40/63, to shoot fixed ammo. I've used 7x57R, 9.3x72R and Hornady 405 Win, in mine. They say that the thinner rims of the 7 & 9.3 can cause headspace problems but, I've not had anything happen in mine. I load them out, when fire forming.

Frank

I did this several years ago, when you had to make the case out of whatever.  I had some 7x57R cases for a drilling, so I annealed the necks and shoulders with a propane torch, looking for a color change like military 30-06, quenched them in water.  Then stuffed them full of whatever powder I had on hand and poked the necks full of "play dough" and fired them.  A slice of raw potato would work.  Did not split a neck.  They were a little short and the rims aren't quite big enough for my Ballard extractor to completely extract every time.  Need to bonk them with a ball peen hammer next time they are fired.   

I had haunted ebay reloading and I came up with a 330 grain Winchester mold, then wonder of wonders, a Sharps paper patch mold needing a bottom plate which I made.  Cant find my load information tonite, so use your imagination conservatively.

James

The ones I've had had a groove diameter of .410 or a little bigger. I shot .412" diameter 300 grain cast bullets. That was from a lyman mold made for the Winchester .405. They shot really well. No need to shoot a 400 grain bullet if you are only shooting 200 yards. I shot them breech seated. I think fixed loads were made with black powder and a paper patched bullet.