I present some data and what I take as a few more conundrums. Thoughts appreciated as they occur regarding the loading of a .40-.38-55 ML cartridge rifle.
Without the 1.5" 12X Unertl scope the gun weighs ~19#. Obviously a Highwall action, the barrel is 28-5/8" long, 1.21" flat to flat, 9 grooves and 18" twist and made with leaded steel, either 12L14 or 40L41. Bore and Groove are approximately .397" and .404" respectively. The groove width is ~.10" and the lands are ~.030" wide. The chamber is cut for the Winchester .38-55 case, though it is not wholly clear which style at this point. The barrel is choked and while slugging there was no evidence of variations in diameter other than the choke.
Without a bore scope to verify this, it appears there is a possibility the chamber is actually an insert. There is no extractor for the case, but a small cut out on the radius of the breech end of the barrel to allow one to hook the case with a fingernail or Bowie knife, whichever is available I suppose.
The Mos mould is a form somewhat typical of his style with 5 small grooves in the range of .010" depth, a short radius nose form with large meplate. They cast in the range of 341-344 grains depending on alloy and mic .403 diameter x 1.097" long.
A chamber cast suggests the dimension from breech face to leade is 2.21". Approximately 1/4" from the breech face the O.D. is .423". At what would ostensibly be the case neck the diameter is .4115".
Where I stop to ponder goes to the simple point of available brass and length.
Production from W-W for standard .38-55 has a nominal OAL of 2.080" for the lot on hand.
W-W .38-55 basic is 2.241". The basic case holds 57.9 gr.of Swiss 1.5 fg by weight, or 55 gr. by volume without use of a drop tube.
As you might imagine the bullets will not fit in the brass, but will seat easily against the respective case mouth of each type of brass. A conversation with Mr. Darr several years ago provided me with several useful pieces of information.
1. "The gun will shoot better than you can."
2. "You need to replace the missing range rod."
3. "Seat the bullet .075" off the case mouth/chamber leade."
4. "Don't use smokeless powder."
I don't know if I'm worthy, but I'm going to give it the old college try. See the above for insight about how I purchased this gun for a song.
On topic of case length, where would you start with this?