Over-sized revolver slugs & accuracy

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  • Last Post 21 January 2026
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Katadin4570 posted this 08 January 2026

I’m curious if other ‘lead heads’ have seen the accuracy and statistical ballistic benefits I have in running ‘oversized’ slugs through their SA firearms. I’d like probe this subject matter without wading through reams of historical subject matter to find a relative thread…, so here goes.

It occurred to me that both of the historical approaches to enhanced accuracy with SA and DA revolvers may not ultimately provide the pinnacle of precision. Those have been, .001-.002” over groove diameter and .0005”-.001” over cylinder throat diameter. And, of course, numerous variations of each.

It occurred to me that many revolver cylinders incorporate a leade, or ‘short throat’ if you will, just ahead of the chamber culminating in the throat. If this is the case, why not handload incorporating consideration for this mechanical reality as one would for a rifle chamber…? So I did, which of course means that I sized projectiles for the origin of the leade and not the throat, ie, fat bullets.

Long story shorter, I’ve found the results to-date clearly indicat an advantage in accuracy and ballistic consistency with this approach. I’ve employed alloys of 8-10 BHN with no appreciable signs of pressure increase and velocities running to 1100 fps. Interesting huh? I plan to investigate this theory much further with additional calibers [began with the 45 Colt], but am very pleased with results thus far…thoughts?

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RicinYakima posted this 09 January 2026

Yes, go back and wade through the historical data, and you will know why. There is no shortcut and the answers you get on the internet are always suspect. 

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Katadin4570 posted this 09 January 2026

Thanks Ric, I don’t mind wading (researching) as long as I’m in the right pool…, or lake. But without a search mode at CBA to narrow down the grid, how does one reduce the field of subject matter, or with whom (member of similar interest), would one begin the search? Suggestions?

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pat i posted this 09 January 2026

If I'm picturing what you're doing right the beginning of the leade is .480 and the throats are in the .451 area and not knowing neck thickness but assuming around .010 what are you sizing your bullets to? Also it would seem to me you'd have to seat the bullet really deep or use a really short bullet to make up for not putting any of it into the actual throat. Are you using a wadcutter seated almost flush with the end of the case? Interesting and maybe I'm not picturing what youre doing right.

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Katadin4570 posted this 10 January 2026

Yes Pat, the lease is .480 tapering to .453” throats (all uniformed). Brass is Starline at averaging .011” wall thickness. To date, sizing for the leade, I’ve run .455” projectiles (280 gr MP SSA SWCs) with very good groups (sub 2” at 25 yds in low light) at 999 fps with an SD of ‘3’. I know, from previous experience, that I can push sizing up to .456” and still chamber cartridges without difficulty. I’m going test this probability as well.

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Katadin4570 posted this 10 January 2026

By the way Pat, the alloy is a Sae

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Katadin4570 posted this 10 January 2026

Saeco 6.5, or BHN of 9+

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pat i posted this 10 January 2026

Interesting. Keep us informed on trying .456 bullets. Does it shoot better doing what you're doing over sizing the bullets to the throat?

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Katadin4570 posted this 11 January 2026

Yes, thus far, greater accuracy and improved statistical ballistics. I’ll post findings as I investigate further.

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GBertolet posted this 20 January 2026

I have a S&W 25-2 45acp revolver. It has .456 cylinder throats. I have an old Lyman 225 gr RN mold, which drops bullets cast of WW @.455. I tumble lube them with LLA. They seal off the cylinder throats well, with no leading. The typical .452 cast bullets lead like crazy in this revolver. I made up a larger expander plug, to handle these .455 bullets. The loaded cartridges, surprisingly, drop into the cylinder with no issues. No problems having these soft bullets, in firing, swage down from .455 to the .451 barrel. Gun shoots great.

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Katadin4570 posted this 21 January 2026

I finally had an opportunity this afternoon to re-test and triple check my findings regarding my earlier premise. In summary, I’ve found that projectiles sized to the actual throat diameter [.453” in my case] provided the best repeatable accuracy in my Ruger test revolver. However, bullet profile is a deceptive factor. Round nose flat points, particularly those of greater weight with longer noses, will give greater accuracy than semi-wadcutters of the same size as diameter increases, creating sort of “mirage” in test results. Now, having said all that, I did find that load ‘stats’ did improve with fatter bullets, IF, one started with an accurate load to begin with. This would seem logical because a larger, tighter fitting stopper in the mouth keeps things in the bottle longer. Interestingly though, pressure increase was never an issue, ie, primers showed no signs of flattening. In my mind this condition persisted because the slug weights remained the virtually the same throughout the test regardless of their size with one exception. At .456” bullet diameter, only 1 chamber required a press fit of the cartridge. Case diameter, with the bullet seated properly [MP 45-270SAA SWC], & sized in a modified, old style [no carbide insert] die to a maximum of .459” body diameter using Starline brass, chambered without a hitch. Chamber diameters, in this Ruger NMBH revolver, were pinned at .480 to .481”. So now, having satisfied my Missouri ‘show me’ penchant for visual evidence, I’ll size my projectiles accordingly and shelve testing and start shooting!!

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