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Making 40-65 Ballard Everlasting cases (Read 266 times)

cheatin_charlie Senior Forum Member Offline Posts: 401 Location: ohio Joined: Jan 10^th, 2009	Making 40-65 Ballard Everlasting cases Sep 10^th, 2025 at 6:17am	Print Post
	I replied to a thread in WTB 40-65 Ballard cases but I thought I would put it here in case anyone was interested. I have an early Ballard #6 in 40-65 Everlasting. Nobody has dies that I could find. CH4D said they have never made dies for that case but if I sent 3 fired cases they could make dies but would take 2 years and cost $500 as I remember. I have made them from 405 WCF but needed to wrap tape around head of case to center it in chamber then fire formed it. Rim is small and thin for my chamber. Other way as I have made them use 45-90 starline cases. Size with 40-70 die down as far as you can to the rim. Then lathe turn head of case to fit chamber. Mine needs to be .480 dia. Then I had to take .020" off rim dia to make fit. Then you have to decide how to correct the rim being too thin for your rifle. I had a choice to make. Make shims to slide onto case or move rim forward to make thicker rim. I have done both at one time. Another problem. .405 cases are not being made at this time but 45-90 Starline are at Midway. Next problem my Ballard takes .413 cast bullet. After firing the case mouth is about .010 to .012 thou. bigger than bullet. Do not want to resize the whole case so made neck sizing die to just size neck to hold bullet. A lot of work but can use original barrel. Also if moving rim foreward you will need custom shell holder. Going to cast bullets now if I can be of help let me know. Charlie


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frnkeore Frequent Elocutionist Offline Posts: 7482 Location: Central Point, OR 97502 Joined: Jun 16^th, 2010	Re: Making 40-65 Ballard Everlasting cases Reply #1 - Sep 10^th, 2025 at 12:56pm	Print Post
	Since you have a lathe, you could turn cases from stock. I've done that for several calibers, just to get the case capacity I wanted. You could also turn just the case head and rim, like another thread on here. How thick is the rim?

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George Babits Frequent Elocutionist Offline Posts: 1126 Joined: Sep 27^th, 2012	Re: Making 40-65 Ballard Everlasting cases Reply #2 - Sep 10^th, 2025 at 1:27pm	Print Post
	I don't know if there is a difference between the Ballard 40-65 everlasting and the Ballard 40-70 straight. I have an original Sharps chambered for the 40-70 Ballard and make brass from 9.3X74R cases. But, the Bell 40-70 SS and Hornady 405 seem to just as work well. I never got concerned about centering them to fire form, but they seem to work just fine. George


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marlinguy Frequent Elocutionist Offline Ballards may be weaker, but they sure are neater! Posts: 17108 Location: Oregon Joined: Feb 2^nd, 2009	Re: Making 40-65 Ballard Everlasting cases Reply #3 - Sep 10^th, 2025 at 3:07pm	Print Post
	George Babits wrote on Sep 10^th, 2025 at 1:27pm: I don't know if there is a difference between the Ballard 40-65 everlasting and the Ballard 40-70 straight. I have an original Sharps chambered for the 40-70 Ballard and make brass from 9.3X74R cases. But, the Bell 40-70 SS and Hornady 405 seem to just as work well. I never got concerned about centering them to fire form, but they seem to work just fine. George The Ballard .40-70 and the Ballard .40-65 aren't really even close. The .40-63 Everlasting and .40-70 Ballard are identical externally, and both are almost identical to the .40-70SS, but none of those three are like the .40-65 Ballard. 9.3x74R cases aree OK to use, butt rims are quite a bit smaller, and occasionally when chambering cases made from the 9.3x74R the rims can slip past the extractor, especially on well worn rifles.

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cheatin_charlie Senior Forum Member Offline Posts: 401 Location: ohio Joined: Jan 10^th, 2009	Re: Making 40-65 Ballard Everlasting cases Reply #4 - Sep 10^th, 2025 at 3:23pm	Print Post
	On my rifle the rim thickness is .080 thou. I made shims .015 thick to make 45-90 cases work. Do you have an 40-65 everlasting case? I would like to know what the brass thickness is at the neck. I am guessing .017 to .020. Charlie


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marlinguy Frequent Elocutionist Offline Ballards may be weaker, but they sure are neater! Posts: 17108 Location: Oregon Joined: Feb 2^nd, 2009	Re: Making 40-65 Ballard Everlasting cases Reply #5 - Sep 10^th, 2025 at 4:45pm	Print Post
	cheatin_charlie wrote on Sep 10^th, 2025 at 3:23pm: On my rifle the rim thickness is .080 thou. I made shims .015 thick to make 45-90 cases work. Do you have an 40-65 everlasting case? I would like to know what the brass thickness is at the neck. I am guessing .017 to .020. Charlie I have no .40-65 original cases. Like most guys I had to make cases from other brass. My .40-65 rifle has a .411" groove diameter.

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cheatin_charlie Senior Forum Member Offline Posts: 401 Location: ohio Joined: Jan 10^th, 2009	Re: Making 40-65 Ballard Everlasting cases Reply #6 - Sep 10^th, 2025 at 7:27pm	Print Post
	Just so people who read this understand. We are not making 40-65 Everlasting cases only cases that can be used in Everlasting chambers big difference. Charlie


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rmc Participating Member Offline Posts: 46 Joined: Oct 23^rd, 2009	Re: Making 40-65 Ballard Everlasting cases Reply #7 - Sep 11^th, 2025 at 4:27pm	Print Post
	cheatin charley I just saw your post looking for cases for a 40-65 Ballard everlasting. I have a box of 50 new never loaded cases the correct dimension for your Ballard chambering. All the published info for these cases is incorrect except in Dutchers Book on Ballards. His dimensions are correct, and these cases were made for an original ballard but unfortunately the fellow past away before they got made, back around 2008 so I have them still, If you want the 50 rounds for $200.00 plus postage I will sell them, let me know if you want them. RMC Dave Casey


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cheatin_charlie Senior Forum Member Offline Posts: 401 Location: ohio Joined: Jan 10^th, 2009	Re: Making 40-65 Ballard Everlasting cases Reply #8 - Sep 11^th, 2025 at 6:51pm	Print Post
	It was not me it was someone named HELP in FOR SALE section. Charlie


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rmc Participating Member Offline Posts: 46 Joined: Oct 23^rd, 2009	Re: Making 40-65 Ballard Everlasting cases Reply #9 - Sep 11^th, 2025 at 11:24pm	Print Post
	cheatin charley, sorry my mistake rmc


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