This is strange....
When I bought the rifle in 2009, I ordered it in .40-65. But for some reason I decided I had to have a chambering that was in the original Sharps line-up. So back to the factory for the 40 cal 2 1/2 (40-70 Sharps Straight) in a new Badger 1:16 barrel in 2010. While I had the 40-65 I bought a Redding .40-65 competition seating die. The expander button size (from BACO) was recommended by a friend, at 0.476". After getting the 40 cal 2 1/2 barrel, I kept using the BACO expander button....for over 14 years.
But with the recent emergence of some cases being difficult to chamber and not having a FL case sizing die, I had a brain fart. Maybe the recalitrant part of the case is in the upper inch+ or so? Here's this Redding Competition bullet seating die on shelf...what if....
Removed the guts of the die, tried a known problem case in the rifle, lubed the case and passed it through the Redding die body. Tried the case in the rifle and it went right into the chamber. More farts....maybe the BACO expander button is a bit large, even though I have two other Redding expander buttons, 0.406" and 0.4065".
Tried both Redding buttons after going through the Redding seating die body and they both worked (but so does the original BACO button). Maybe the BACO expander button is increasing the OD of the upper part of the case just enough to produce difficult chambering?
So the current plan is....
Use the Redding seating die body, then use the Redding 0.406" expander button and load some up to see how they chamber. If they chamber OK shoot them. In the meantime get a Redding FL sizing die on order. They are out quite far today.
Tom