Hello everyone. I have a Puma M92 stainless lever gun in .454 Casull which has a poor accuracy problem. I got the gun maybe more than 10-15 years ago when I was a newbie and didn't knew much about firearms. The accuracy when it was new was great, I remember shooting 2" groups at 100 yards with factory copper jacketed ammo. Then one day somebody gave me two boxes of reloads with cast lead bullets which were loaded very hot. After shooting 25-30 rounds I realized the bullets caked the barrel with lead really, really badly. Thinking back, I assume the bullets didn't had gas checks. Once I got home I started cleaning the barrel with the 45 brush and Hoppe's, but it was just.. hopeless. I put chore boy around the brass brush, lead kept coming off but it was like never ending, couldn't get all of it out. Somebody told me about lead cloth, I got one, cut it in small patches, ran 15-20 of them through the barrel, then more brush with chore boy, then another 15 patches of lead cloth and I finally managed to see the barrel free of lead. I think I scrubbed that barrel a total 4-5 hours put together.
Couple of years later I started reloading and I cast my own .452 diameter bullets with gas checks for plinking. Accuracy wasn't such a big issue and I didn't paid much attention since I like to shoot steel gongs at 50-75 yards and the rifle with my cast boolits reloads was OK for that. But last month I got drawn for a premium area deer hunt (I live in California so that's a big deal for us) and I decided to start reloading using 250 grain, .451 Barnes copper solids for this upcoming hunt (we cannot hunt with lead bullets in my stupid socialist State). So I tried different loads starting with Win 296 and H110 from low to high, and the accuracy was bad on every try, like 2-3 inches groups at 50 yards bad. I started thinking maybe I ruined the barrel years ago when I scrubbed the hell out of it so I took the rifle to a gunsmith to look inside with a borescope and slug the barrel. Today I went and picked up the rifle. The gunsmith told me the rifling is good, there is no damage or noticeable wear, and that the measured bore diameter is .4555
First thing that hame though my mind: isn't that a little too wide for a .451 Barnes bullet riding through the barrel? I'm thinking that may be the cause of poor accuracy. The regular copper jacketed bullets are .452 could that make a difference in accuracy? I looked for slighter larger diameter copper solid bullets online, the closest are the .4580 diameter used in 45-70 caliber. Would it be wise to try a few considering the diameter of my rifle barrel measured by the gunsmith is .4555 (the .458 bullet is only .0025 larger than the diameter of the barrel)?
What do you guys think? How can I fix this problem and increase the accuracy with solid copper bullets for this hunting season? Should I try the .458 or do you think that may cause over pressure and blow up the barrel?