Of course they were balloon cases - click here and scroll down
Chasing the 44-40 - Pressure Testing:
Thanks, has anyone watched the little video clip at the beginning of that webpage? That is one ugly *** that has an attitude as big as his fat belly.
Correct, early 44-40 WRA (Winchester) cases were of the solid head design but incorporated the large balloon pockets. These pockets gradually decreased in size. Some later cases had a simple little "bump". As the pocket size decreased, it would appear from test results that pressures and velocities decreased. The earliest published pressures I have seen is a WRA Cartridge Engineering document stating that the Service Pressures for the 44 cartridge used in the Win 73' is 13,000cup and the service pressure for the cartridge used in the 92' is 18,000cup, obviously referring to smokeless powder use.
Pressure test that I was able to make yielded the following;
Early red label smokeless boxes had labels on the bottom of the box telling folks to never reload them...but eventually dropped with no change in powders or charges.
One would think the FFFg may be more powerful than FFg powder. This may be correct but test examples proved otherwise. What proved more powerful was the quality of the powder rather than the granulars.
Correct, Your Milage May Vary!!!
In the black powder tests I ran in 2018, Swiss FFg yielded higher pressures and higher velocities compared to the same charge of Goex FFFg.
For those that still think you can not get 40gr by weight into a case, these powders were compressed from between .17" to .19" or so, with modern Starline cases being able to contain 40gr by weight of Swiss FFg and Goex FFFg with .21" compression.
These Solid-Head, Semi Balloon Pocket cases, much stronger than the folded head type, were still not as strong as today's modern cases with no balloon pocket.
John Kort wrote some great posts on the subject:
Chasing the 44-40 - Two Peas In A Pod by John Kort
Back to the revolver, pending condition from age, (all anyone can do is guess at this by an inspection, even a gunsmith) as long as the bore is no smaller than .427", Buffalo Bore's .428" load should work with no problems. However, personally...I too would take it easy on the ole girl and not shoot such harsh loads.