I use the 44-40 in a S&W 544 and have loaded for it to use in a Marlun 1894S. I just stopped using anything but the slightly thicker Starline brass for reasons you can glean from above. The Nolser 200 grain JHP is a clean, accurate bullet, but hard to find in the current panic. I've been using 200 grain Missouri LFN and those are excellent as well.
You just have to be prepared to crush/ruin a couple of cases to find the most roll crimp you can apply. I use RCBS dies and have had no troubles, no setback, and no bullets moving forward (revolver) using this method. I gave away my Win and Rem brass years ago.
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