Wad Size

[Half Dog]

I have a 1860 Army 44 cal revolver. Is it better to use a 7/16" or 1/2" hole cutter to cut the wads?

Thank you in advance for your input.

[Omnivore]

Not enough information. If you're loading loose components, then use the half inch punch. On the other hand, if you're making cards you'd want an in-between size, around .450". If you have an original Colt, then you'll want closer to .454" for a card. For a felt wad, the half inch would be better for either.

I use a punch closer to your 7/16" for making cards and pills intended to go into paper cartridges, making lube cookies (card, lube pill, card). That way, the cartridge maintains a taper and thus loads much more easily into the chamber of a Colt. It's easier for the Remington also, but more critical in a Colt where you have no direct, straight-line access to the chamber like you do with a Remington.

The default assumption would be that you're loading a repro with loose ammunition including felt wads, and so; half inch.

7/16", (.438") is about equal to, or smaller than, the typical repro 44 chamber, and a tighter-fitting felt would probably be best. Half inch felt will easily thumb into a chamber.

[Outpost75]

I got a .455 diameter wad punch from Buffalo Arms for only $18

http://www.buffaloarms.com/hammer_struck_wad_punches_pr-4111.aspx

[Idz]

I made one that punches 15/32" (0.470") x 1/8" felt wads for my 44 cal revolvers that works well. A 1/2" may be a bit tight if you wax the wads.

[Hellgate]

I've used the 7/16" hole punch to make thousands of felt wads for my C&B 44s. It helps to hog out the channel the wads travel up through as you punch them out. I use a drill press on low speed over a wood base and chuck the 7/16" punch into it and punch out the 1/8" thick F-1 SAE felt. Then I lube them with any number of formulas like 50/50 bees wax & oilve oil, Beeswax & lard, etc.