I have a 99% Smith 696 .44 Special. It is a beaut.

My question is: What is the reasonable, practical max pressure in cup for this gun? And the approx max “safe” velocity expected, always using 240-260 gr hard-cast SWC or Keith-type bullets.

I realize the "ole cowboy gun" issue and the liability issue for ammo manufacturers.

Let's do a comparison:
My .44 Special is a 35.5 oz stainless 696 no-dash; made in 1996. I also have a 25 oz Smith .357 Mag 640-1 in stainless; made in 1996. The .357 Mag is SAAMI-spec'd at 35,000 cup, whereas the .44 Special is spec'd at 15,500 cup.

When I measure, with my Starrett dial and hand-mikes and compare the two guns, the .44 has more steel all-around than the .357.
Cylinder notches in both guns are offset from the chamber for better strength.

Steel between adjacent chambers:
.357 mag: 0.126"
.44 Spec 0.158"

From chamber to cylinder outside:
.357 mag: 0.061"
.44 Spec 0.067"

Top strap thickness:
.357 mag 0.180":
.44 Spec 0.205"

Forcing Cone wall thickness @ 0.2 inches into barrel:
.357 mag: 0.105"
.44 Spec 0.106" (essentailly identical)

It looks like the .44 Special is a stronger gun all the way around, and likely the same stainless as used in the 640-1. Will the 696 safely handle a 240 hard-cast @ 1100 fps without stressing the gun? Probably Unique, H4227 or 2400 powder, or other suitable powder.

Right now, Tim Sundles @ Buffalo Bore makes a 255 SWC @ 1000 fps that he says is safe for all .44 Special made guns other than the Charter Arms Bulldog. So I know we're good to go at least to 1000 fps with a proper powder.

I do have a model 29 and I’m not trying to make a magnum out of the 696.

I am familiar with high pressure indications such as hard extraction, blown or flattened primers, sloppy primer pockets, extruded primers, etc. But I want to be able to use a reasonably-maximum load for those times when I may be in the woods. And I’d like your opinion on the relative strength of my 696 versus the Smith 640-1. Are these two guns basically similar in strength?

I have ordered Brian Pearce's article (June Handloader, issue #260) which deals with higher-pressure .44 Special loads (around 25,000 cup)

Thanks for your reply in advance,
Sonny