So I'm trying to wrap my head around this. The revolver stuff seems easy...Chamber size and bore size. The lever actions got me a little more stumped. This is some information I found, but you guys tell me what else I need to know:
"Most Marlin Microgroove .44 barrels I have measured run .430-.433" in diameter. The easiest solution is to get a mold which casts .432-.433 and to cast bullets SOFT, no harder than 12 BHN, wheelweights are OK, then lube the as-cast and unsized bullets with 45-45-10 or Lee Liquid Alox and load them into sized-expanded brass to depth only. Then SEPARATELY crimp them using either the Lee Factory Crimp Die or the Redding Profile Crimp. This will ensure cartridges will enter the chamber, and if necessary the bullets will be lightly sized by compression inside the case. In my experience the Lee FCD is MUCH more difficult to use and adjust correctly. The Redding die is far superior if you follow the instructions.
To make a "pound cast" for a .44 Magnum rifle the easy way is to take a dead soft, pure lead .457 round ball, drop it into the chamber. Then use a 3/8" diameter brass rod to drive the ball just barely into the orig of rifling and knock it out. If you don't over-drive the ball you will capture both the chamber mouth diameter and the chamber transition from the case neck to the "throat", or conical "forcing cone" section at the origin of rifling."