44-40 from 38-40

Ok I have converted a number of .38/40 cases without any failures. Kinda surprised me but it works.

1. Use new cases. I tried some odds and ends of fired .38/40 cases and some were such that my Lee sizing dies would not size them small enough to chamber in my Winchester 66 reproduction.

2. Expand the case neck. Best was a 44 cal Lyman M die, 2nd best was an RCBS 44 Magnum expander, last choice would be the Lee expander. Run whatever expander you use as deep as you can to open the neck as deeply as possible. Stop before you split the case mouth.

3. Run the case into the sizing die fully. Make sure the brass you’re using will chamber in your firearm.

4. Then flare the mouth and load as normal. There will be a wasp waist at the base of your bullet, but most factory loaded .38/40 and .44/40 has a cannelure rolled at the base of the bullet to prevent bullet set back. Didn’t fire any so I don’t know about case splits upon firing.

Another way that would probably work is the Cream of Wheat method. Prime your .38/40, use 2-3 grains of Bullseye, Red Dot, 231, etc. fill the case nearly full of cream of wheat or corn meal. Twist a bar of soap over the case mouth as a plug. Fire and out should pop a nicely fire formed .44/40 case. With this method start with a light charge and increase by 1/2,grain until the case fully forms. Don’t fire these rounds indoors and do this at your own risk. Or watch Starline’s website for .44/40 brass to show as in stock……..I’d probably stick with the mechanical method. Price and availability of primers being what they are.