These are the 3 bullets I have been working with in my .44-77. All are from BACO and all have been modified at least some. BACO makes excellent molds by the way!
Left to right the first is #441505EPP which is a 2-Diameter bullet that I modified the base diameter on to be to .300" long to reduce the powder charge from 90+ grains to 86 grains.
The second one is #430520 which I modified to .433" diameter because it was just too small for my bore. I often refer to this as my Metford bullet because it closely resembles Metford's design from the 1870s.
The third one is #431ADJ which actually cast at about .4305" and was too small in diameter so I modified it to cast at .4345" so I could use 55W paper.
The 441505EPP shot really well with a 2016 lot of Swiss 1 1/2, but I only had 4 lbs. of that lot. When I switched to my 2013 lot last year it didn't like that lot at all. I modified the base diameter length to match the seating depth, .180", that works so well with my Metford bullet. It shot better at 220 yards but showed a lot of vertical at 600 yards, about 3 moa.
The 431520 loaded over 86 grains of Swiss 1 1/2 and a .060" LDPE wad seated .180" deep with .100" compression in BACO brass and using Remington 2 1/2 large pistol primers shoots very well at 200 and 300 yards. It shot well at 400 yards too, but I have struggled to get hits on all the gongs at local matches at 500 and 600 yards. I have not shot it on paper yet at 500 and 600, but I have shot it at 800 and it seemed to do well in some pretty tricky conditions back in May at Lodi.
I have been using the exact same load for all three of these bullets. This was the result of a fair amount of testing to find the powder charge that worked best, the compression that worked best and the primer that worked best. All of this testing was based on the Metford bullet but has transferred over to the other two bullets well. Some tweaking may be necessary for each bullet, but they all shot well at 220 yards on my home range. I do not have access to a longer range near me so all longer range testing is done at matches.
The 430ADJ bullet (.4345" dia.) is the bullet I shot the group with in my opening post here. With the mold set at 1.375" long it weighs 500 grains +/-. My thinking on going to this bullet was 1) to try the thinner paper and 2) to try a shorter bullet that would be spun fast for it's length in hopes of being more stable. I really don't know where I got the idea but that was my thinking.
I believe somewhere in this thread or back in the one under Reloading/Black Powder Cartridge Don mentioned something about a 1.3 something bullet shooting really well in his 17-twist .44-77 and that probably planted the seed for trying a shorter bullet. Don has also mentioned more than once that 55W and 55Y work very well for him in his .44s. I have resisted the thinner paper until now.
After patching about 50 bullets I think I've got it wrapping pretty well and I am almost starting to like it. If this 500 grain bullet shoots well at Rapids on the 31st I may have to continue the thin paper experiment on to another bullet, my Metford bullet would be the logical choice.
The ammo is all loaded and I have a really busy week coming up, I will get home Thursday just in time to throw everything in the car and head to Rapids on Friday. It's a one day match on Saturday and the weather at this point looks dry and hot so with luck I'll have a better idea if this 430ADJ bullet will hold center at 600 yards by the end of the day on the 31st. I do have enough of the Metford bullets loaded to shoot the match if the ADJ can't find paper.
My results will get posted here one way or the other. Stay tuned!