I have enjoyed reading this thread again also. The following article appeared in The Fouling Shot issue #262
Retired “cop guns” still “serve and protect.”
Standard-Pressure .38 Special Loads for the Revolver and Cowboy Rifle
C.E. “Ed” Harris, Gerrardstown, WV
"Were it necessary for the average shooter to own and use but one revolver, it should be a .38 Special." J.S. Hatcher, Textbook of Pistols and Revolvers (1935),
From the post WW1-era until about 1980 the most widely used police handgun in the United States was a revolver chambered for the .38 Special. Introduced as a black powder cartridge in 1902, S&W simply lengthened the .38 Long Colt case from 1.03” to 1.155” to hold a heavier 21-grain vs. 18-grain black powder charge and increased its bullet weight from 148 to 158 grains. But, the most important improvements were optimizing the barrel and chamber dimensions to correctly guide and support an “inside lubricated” bullet of adequate diameter to fit the cylinder throats and the groove diameter of the barrel. S&W established these principles years earlier in perfecting the .44 Russian black powder and later .44 S&W Special smokeless cartridges, which greatly improved target accuracy.
Traditional .38 Special police service ammunition featured a 158-grain, lead round-nose, wax-lubricated, cup-based bullet of soft lead, propelled to 855 +/- 25 fps as measured from a 6-inch solid industrial test barrel. Typical revolver velocity was about 700 fps from a 2-inch snub, 800 fps in a 4-inch service gun, and about 840 fps in a 6” target revolver. Actual test results of vintage ammo depend upon manufacturing variations in barrel groove, cylinder throat diameter, and cylinder gap.
[The expected Delta-V with standard-pressure lead .38 Special ammunition is about 10 fps for each 0.001” change in barrel-cylinder gap from Mean Assembly Tolerance of 0.005-0.006”. Therefore, a 2-inch gun assembled at minimum tolerance (0.002” pass/0.003” hold) could theoretically produce higher velocity than a 4-inch gun at the customer service maximum (0.008” pass/0.009” hold)- Ed.].
After WW1 black powder loadings were replaced by smokeless. Hatcher (1935) described typical factory charges of 3.6 grains Hercules Bullseye, 18 grains of King’s Semi-Smokeless or 4.2 grains of Infallible. Once smokeless powder loads were adopted, the .38 Special became and remained the standard for US law enforcement and target shooters, making the .38 Long Colt obsolete by 1920.
The .38 Special is the most accurate revolver cartridge ever developed. Ten-shot groups fired from industrial test barrels or the best target revolvers are routinely 2" or less at 50 yards. Colt, Ruger and S&W police service revolvers were expected to produce groups of this order when firing common duty ammunition of average quality at 25 yards. Good revolvers often did much better with wadcutter loads. If you don't currently own any handgun, but have been thinking about getting one, you really can't go wrong with a sturdy .38 Special (or .357) retired “cop” gun. For this very reason the .38 Special still enjoys great popularity in US states where civilian concealed carry is permitted.
“Mid-range” target 148-grain wadcutters are ideal for general use. They are accurate, give a good knockdown blow on small game, and don't destroy much meat. They are a valid choice for personal or home defense carry in "airweight" or aluminum alloy-framed guns which cannot handle +P loads.
“Full-charge” wadcutter ammunition, which was loaded to “service velocity” was produced by the big ammunition factories for police academy and in-service training use prior to about 1970. The equivalent can be assembled today by hand loaders using cast, solid-based 146-148-grain wadcutters and 3.5 grains of Bullseye or TiteGroup. Factory loads are available from Buffalo Bore.
The ideal .38 Special general-purpose load for dual-use in revolvers and cowboy rifles is a cast lead ogival flat-nose “Cowboy” bullet weighing 145 to 160 grains. This feeds reliably in lever actions, and is “speed-loader friendly” for revolver use. Hard bullets are neither necessary nor desired. Soft lead of 8-10 BHN is best. Range backstop scrap or 50-50 plumber’s lead and wheel weights with a bit of tin added to improve fill-out is good. Frugal shooters value the fact that 3.5 grains of Bullseye or TiteGroup loads 2000 rounds from a pound of powder, to closely approximate factory ammunition.
Standard-pressure .38 Special ammunition (SAAMI MAP 17,000 psi max.) is most economical and practical for general recreation, field and utility use. It does not make your hand sting or your ears ring. It is more accurate out to 50 yards or meters from a revolver or 100 from a rifle, than anyone over age 50 can shoot with iron sights. A revolver dispersion of “one inch per ten” (yards) is considered acceptable for “service-grade” loads, but the best lots of 158-grain lead round-nose or semi-wadcutters approach the grouping expected of match wadcutters.
Carefully prepared hand loads with factory bulk-packed Remington 148-grain hollow-based wadcutter component bullets and 3.0-3.2 grains of Bullseye produce 2 inch, 6-shot groups at 50 yards or better from a test barrel or carefully assembled target revolver. My test platform is a Unertl-scoped BSA Martini-Cadet with 1:20” twist Green Mountain barrel and .38 AMU chamber. My best Remington-UMC, Bridgeport, CT wadcutter from the 1950s averages 1-1/2” ten-shot groups at 50 yards. A service-grade Colt, Ruger or S&W revolver will usually do about three to four inches at 50 yards firing from Ransom Rest. A good target revolver can shave an inch off that. Any well turned out .38 Special is fully adequate for field shooting small game and varmints, as well as for home defense duty.
“Traditional,” (not +P) standard-pressure factory .38 Special 158-grain lead ammo, produces about 1000 f.p.s. from a 20-inch Cowboy rifle, approximating the energy of .38 Special +P ammunition fired in a 6-inch revolver, but with lower noise. Good cast bullet hand loads will do the same with good accuracy IF your bullets “fit” the cylinder throats, and you use moderate charges which produce uniform, subsonic rifle velocities, which avoid transonic buffeting.
In .38 Special the velocity and pressure of standard 158-gr. lead factory ammo is matched by loading either 3.5 grains of Bullseye, 4 grains of 231, 452AA, or WST or 4.5 grains of WSF, 473AA, Universal, AutoComp, Unique or Herco. Typical velocity data is summarized in Table 2.
[+P loads are beyond the scope of this article, and will be addressed separately in a future entry to The Back Creek Diaries].
The Saeco #348 double-end, bevel-based wadcutter, cast 8-10 BHN, loaded unsized, and profile taper-crimped into the crimp groove, at 1.20” OAL over 3.5 grains of Bullseye is a full charge, but standard pressure load giving about 860 fps in a 6-inch revolver having 0.004-0.006” cylinder gap. It averages 2 inches or better at 50 yards at 1030 fps from my 25-inch BSA Martini with 6X Unertl scope and does nearly as well when feeding it as a “two-shooter” from my Marlin 1894 Cowboy II.
Wadcutters do not produce linear dispersion when target range increases very much beyond about 50 yards or meters, when shot from the standard S&W 18-3/4” twist barrel. A faster twist of rifling, such as the 1:10” used in 9mm Parabellum barrels and some custom PPC guns, will shoot very well past 100 yards. I would refer your attention to Bill Duncan’s article in FS 258-19 for specifics.
For dual-use in rifle and revolver ringing the 100-yard gong I prefer either the Accurate 36-155D or 36-159H flat-nosed cast bullets. Those who don’t cast can get good results from the bulk, soft-swaged 158-grain LRN Magtech cup-based bullets, over-lubed on top of the factory blue wax with 45-45-10 or LLA, loaded loading the same 3.5 grains of Bullseye. Speer 158-grain LRN and SWC bullets also shoot well, but are more expensive. All of these feed reliably from lever-actions and are good choices for field utility loads for either rifle or revolver. Hand-held from sandbags revolver groups even with 2-inch guns are “one inch per ten” [yards] or better out to 25 yards. Rifle iron sight groups of 3-4 minutes of angle, being proportional to the range are normal to well over 100 yards.
Norma .38 Special 158-gr. LRN loads fired previously as reference ammunition from my BSA Martini with 6XUnertl scope averaged 3” at 100 yards. Speer and Remington factory swaged lead round nose and semi-wad cutter bullets loaded in .38 Special cases with 3.5 grains of Bullseye averaged about 4 inches at 100 yards. Vintage 1950s factory loads such as Remington Targetmaster LRN, Western Lubaloy, WRA and Rem-UMC Police Service all fell into the same accuracy range.
+P,.38 Special cast loads fired in the Martini Cadet and Marlin cowboy rifles did not group as well at 100 yards as subsonic, standard-pressure factory or hand loads. This is because bullets are subjected to transonic buffeting as their velocity decays below the speed of sound. A good working velocity benchmark for .38 Special Cowboy rifle loads to also be used in a revolver is to seek from 900 to 1080 f.p.s. from a 20-inch barrel, so there is no “crack” to disturb the neighbors.
A flat-nosed .38 Special bullet with meplat 0.6 or more of bullet diameter is effective on groundhogs, wild turkey and larger edible critters raiding your garden, providing through-and-through penetration, with minimal meat damage so that you can “eat right up to the bullet hole!”
Table 1 - 38 Special Factory Loads - Velocity vs. Barrel Length
_________________S&W Mod.10, 2” S&W Mod.10 4”__ S&W HE 6”____BSA Cadet 25”
------------------------0.005”cyl.gap___0.005”cyl.gap_____0.005”cyl.gap___ solid barrel
Rem-UMC 148 HBWC_702 fps, 12 Sd__747 fps, 6 Sd____804 fps, 7 Sd____897fps, 17Sd
WRA SM 148 HBWC__697 fps, 18 Sd__742 fps, 13 Sd___783 fps, 13 Sd___857 fps, 11 Sd
W-W Q4196 158 LRN__728 fps, 24 Sd _793 fps, 10 Sd___814 fps, 19 Sd___958 fps, 13 Sd
Rem-UMC 200 LRN___627fps, 27 Sd__702 fps, 22 Sd___ 747 fps, 16 Sd___895 fps, 15 Sd
Win. 158-gr. LHP +P___831 fps, 10 Sd__920 fps 21 Sd___952 fps, 11 Sd__1093 fps, 19 Sd
Column Mean________717 fps_______781 fps________820 fps________940 fps
∆V from 4”_________-64 fps________Baseline_______+39 fps________+159 fps
Table 2 - Standard Pressure .38 Special Load Data
_________________Ruger SP101, 2” Ruger Serv.Six 4”___Marlin 24”
--------------------------0.005”cyl.gap___0.005”cyl.gap________solid barrel
Saeco #348 146 DEWC, wheel weights, OAL 1.25”
3.0 grs. Bullseye_____691fps, 9 Sd___736 fps, 15 Sd_______804 fps, 17 Sd
3.5 grs. Bullseye_____792 fps, 9 Sd___863 fps, 7 Sd_______1062 fps,5 Sd
4.0 grs. W231_______653 fps, 21 Sd__ 837 fps, 22 Sd______900 fps, 32 Sd
Saeco #358 160-grain “Cowboy” FN, wheel weights, OAL 1.45”
3.0 grs. Bullseye_____650 fps, 26 Sd__825 fps, 18 Sd_______884 fps, 7 Sd
3.5 grs. Bullseye_____711 fps, 14 Sd__853 fps, 21 Sd_______956 fps, 7 Sd
4.0 grs. Bullseye_____809 fps, 13 Sd__901, fps, 12 Sd______1096 fps, 3 Sd
4.9 grs. AutoComp___725 fps, 10 Sd__850 fps, 15 Sd_______1001 fps, 34 Sd
Accurate 36-190T Flat nose, 195 grains 1:30 alloy, OAL 1.53”
2.7 grs. Bullseye_____595 fps, 29 Sd__685 fps, 28 Sd_______789 fps, 12 Sd
3.0 grs. Bullseye_____631 fps, 14 Sd__716 fps, 28 Sd_______816 fps, 13 Sd
3.2 grs. Bullseye_____662 fps, 7 Sd___737 fps, 11 Sd_______865 fps, 24 Sd
4.5 grs. AutoComp___603 fps, 7 Sd___735 fps, 18 Sd_______911fps, 30 Sd