Yes, HBD Ed toomanyletters.

Well, I post now with egg on face.

Apparently, I mismeasured the bore diameter; I discovered the issue when using cylinder gauges to get a better feel for the diameter of the required floating pilot for the chamber reamer.

The bore is 0.412, groove is 0.429 The 3 wide lands in the bore made it interesting to measure, and once I noticed the bore difference, I reslugged the barrel to ensure I had the groove right.

Anyway, its looking much more better for lead with the 0.008 deep rifling, rather than the 0.005.

Still looking at the 44-40 for the cartridge, now the big question is if I can find time to do it before deer season....