Years ago, I was just married and funds were in short supply..had a Snider artilery and 3band. The artilery had a 5 groove bore, the 3 bander 3 tapered grooves like the pattern 53 muzzleloader. I made chamber casts of each. Since I had no loading dies, I turned cases from solid brass stock for a nice close slip fit. I also bored case to hold 70grs. of powder instead of the heavy 80+ of originals..figured my shoulder would thank me later!
groove dia. was around .585"..so I turned up an old style 3 piece "hammer swage"..body was desired bullet dia., base-punch fitted inside hollw minnie base for support & a fitted nose punch to match nose shape. The base punch was adjustable via fine threads..top punch bottomed out on body..for repeatability. I used this in an arbor press & lubed bullets came out a bit shorter in length but perfect fit for bore.
I altered a scrapped little arbor press with fitted nose punch & counterbore for case head..cases never really expanded much & reloading was done at range.
I was getting around 3" at 100yds with those hard to see open sights.