If yer asking me, I've not loaded anything yet but that is what I'd be looking for. I'm going to attempt more accurate readings of my cylinder bores later today.
If the round balls are sized to fit in the chambers with a swedge fit then they are most likely to be under bore size. If the correct alloy is used (dead soft lead) these balls will bump up to bore diameter when fired.
Been working that way for over 100 years now.
I don't think so. Were the chambers on the original Colts and Remingtons under bore size? I realize the contemporary replicas all (it seems) have that problem - at least, most of mine do - but I've not seen evidence that the originals suffered from the same malady. It seems to me that's an incredibly unlikely mistake for the people who were smart enough to design these guns to make.
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