As the FCD worked so well on the .38 I bought an FCD for reloading my .44-40. All looked ok, but half-way through a competition at the range my Winchester jammed! Looked like an empty case hadn't ejected, but when I pulled it out I could see that the boolit had been pushed back into the case!!!! One more shot and it happened again, at which point I stopped shooting it. I ended up using the original roll-crimp die and reseated all my loaded cases.
After much messing around I discovered that if I push an empty case into the FCD the top of the case is flush with the top edge of the crimper, which is what I would expect, however if I put the case into the shellplate and then push the FCD on the case sits lower inside (obviously by the thickness of the top of the shellplate where it grips the rim). This means that the crimp edge is now aligned with the boolit, not the case.
This would suggest that this FCD can't, in fact, be used for .44-40. Anyone else have any experience with this?