THE GUN THAT WAS MADE FIRST BY RUGER FOR THE .44 MAGNUM ROUND. Lately Ruger has produced some special run of guns in .44 Magnum chambering that again have the fluted cylinder feature. Also a few early Bisleys were fitted with FLUTED cylinders in .44 caliber. However most were unfluted roll marked cylinders. But the most important factor we have found here is there is very little difference in strength between a fluted and non-fluted cylinder. The strength of the cylinder can vary more from the quality of the material and the tensile strength of the part due to different points of hardness. When steel is heat treated it can easily vary a couple of points. This is only a few thousand pounds of tensile strength but this is likely to mean more to absolute strength than the difference in the design of the part in the argument between "fluted" or NON-Fluted". The important fact is that the initial part (in this case the cylinder) was OVER ENGINEERED to account for these variables. They are amply strong to safely handle any safe load. To DEFINE SAFE: ANY LOAD THAT DOES NOT EXCEED THE INDUSTRY'S RECOMMENDED MAXIMUM OPERATIONAL PRESSURE.. In the case of the .44 magnum, this is 40,000 CUP. Not to exceed 43,500 ABSOLUTE MAXIMUM.
The Ruger Blackhawks and Bisley models chambered for .45 Colt are approximately 80% as strong as the same Ruger chambered for .44 magnum. This means we can load the .45 Colt to 80% of the pressure of the .44 Magnum round and still maintain the 100% safety level. 80% of 40,000 is 32,000.
To check our findings we again turned to H.P White Labs and their findings paralleled ours. Ruger Blackhawks in .45 Colt caliber were destroyed in controlled test conditions at approximately 60,000 CUP pressure levels.
From an article by Linebaugh