Modern Smokeless Powder

Ironing Out Some Issues

The years 1899 to 1909 was somewhat of a transition period sorting out issues with faster burning (pistol) powders for revolver use. Revolver manufactures advised against the use of ALL smokeless powders until at least 1909. Meanwhile manufactures like Winchester continued to load all of their 44-40 ammunition with the slower burning rifle powders for rifle use. 

After RSQ was phased out by 1911, SR80 (rifle), Pistol Powder #3, #5 and #6 were introduced...as well as IMR #1204, also a rifle powder. Before the magnum powders were called Magnum powders, 2400 and IMR-4227 were introduced during 1932 and 1935, respectively. IMR-4227 directly replaced #1204, but again...Winchester continued to use Sharpshooter rifle powder until about 1938...or until supplies "ran out" by the end of WWII.  By 1949 Winchester switched to a pistol ball powder, a flattened ball powder by 1958 and a flake powder by 1978 for their 44-40 ammunition.

Vintage data on the still newer smokeless powders...only 20 old years at the time...and still confusion between fast burning pistol powders vs slower burning rifle powders being used in pistol sized cartridges.

I did not say Pistol Cartridges nor did I say Pistol Caliber, I said PISTOL SIZED CARTRIDGES

I reiterate;

The 44 W.C.F. cartridge came into this would as a black powder pistol sized rifle cartridge used in both revolvers and rifles by the late 1870's. After 1895, the 44 W.C.F., now referred to as the 44-40 by nearly everyone, was loaded with a smokeless rifle powder load and used in both revolvers and rifles.

The smokeless rifle powders at that time directly replaced black powder bulk for bulk but at nearly half the weight. For the Winchester 44 W.C.F. cartridge, this powder was Dupont No. 2. Winchester did not load the 44-40 cartridge with fast burning pistol powders until well after WWII. By 1976, the 44-40 cartridge was neutered as a rifle cartridge....and here is why.

Jan. 1918 Issue of Outdoor Life :

Editor —Just a hurried note before mail hits here....

...Just another little matter and will close for this time. This relates to reloading the .44-40 Winchester cartridge satisfactorily for a revolver which it has been intimated [to imply or hint] could not be done. With good shells, ideal tools and DuPont No. 80 powder [a Sporting Rifle Powder], I can turn out cartridges which are perfectly satisfactory for me. This is not saying the other fellow might fail to secure satisfactory results with other tools, inferior shells or any old powder he might happen to have. If , however, you contemplate loading with half a dozen different loads better get a gun using a straight shell like the .44 S. & W. Special but for full grown loads the Du Pont No.80 in the .44-40 suits me. Same when used in the .45 Colt.

~B. C. ASHLEY A. HAINES.

[note: SR No.80 (introduced 1913) had load data for both rifle and revolver, this powder was a bit faster burning than Dupont No.2 but slower than pistol powders]

This is a perfect example on why the problem with performance back then was completely opposite than it is now. Back then the 44-40 was loaded as a rifle cartridge (rifle powder), giving poor performance in revolvers...but now it is loaded as a revolver cartridge (pistol powder)...giving poor performance in rifles.

Even during 1937, Sharpe explains the same thing that Haines wrote;

Sharpe's 1937 Handloading Manual,

" The 44-40 is capable of excellent performance when loaded properly for handgun use [fast burning pistol powders]. If, however, one endeavors to combine loading for both handgun and rifle in this caliber, he is destined to meet with only mediocre success. As in all other dual-purpose cartridges, the factory loads are only a compromise at best. Smokeless-powder loading for handguns requires a much more rapid-burning type than loading for rifle use, as the short barrel must burn all the powder if satisfactory results are to be achieved..... " Thus the reason for modern mediocre factory loads using pistol powders."

Meaning that mediocre pistol powder loads results in low performance in both revolvers and rifles, thus the neutered gem that once was a powerhouse, both up close and at longer ranges.....is nothing more than a misunderstood cowboy mouse fart!

In other words, if the shooter wants max performance in both rifle and revolver, the rifle must be loaded with rifle powder and the revolver loaded with pistol powder.

Post 1913 Sporting Powder Rifle No. 80

1920 Dupont No. 5 Pistol Powder

1925 IMR Powder Rifle No. 1204

1935 Hercules 2400 Rifle Powder

1935 Hercules IMR4227 Rifle Powder

By 1937 (Sharpe's Handloading Manual)

Modern Smokeless Powders

For the 44 W.C.F.

By 1978 Winchester switched to a flake powder which dropped the 44-40 performance down to an estimated 1,190fps, from an original 1,325fps, for rifle loads. In order to get the best performance (velocity and distance at lower chamber pressures) out of this cartridge, handloaders have to use slower burning rifle powders for rifle use.

By now most of us know that there are tons of other powders available but slower burning rifle powders fit for the 44-40 are nearly extinct. Thus I am only going to mention a few more for rifle application.

As mentioned earlier...

​"Twenty two years after its introduction, the first .44 W.C.F. smokeless powder cartridge is found in Winchester's catalog No. 55, dated August, 1895. In its manufacture, Winchester used 17 grains of DuPont No. 2 "Rifle" powder which was a "bulk" type smokeless powder patented on August 22, 1893. DuPont's description of "bulk" smokeless powder indicated that it was to be loaded in "bulk" measure just like black powder. 

​In the .44 W.C.F., 17 grs. of DuPont No. 2 Bulk Smokeless occupied the same volume as 40grs. of FFG. Velocity was cataloged at 1,300 f.p.s. To identify the new .44 W.C.F. smokeless powder cartridges from those containing black powder, which looked identical, Winchester put a "W" in a circle on the primer. It would also appear that eventually the "W" marked primers were also used for black powder loads. Dupont #2 had a similar burn rate as today's IMR-4227. However, Unlike 17gr of Dupont #2, 17gr of IMR-4227 is not a case capacity load but is a published load.

​Du Pont #1204, introduced in 1925, was directly replaced by IMR-4227 in 1935. 25gr to 30gr of #1204 was used in the 44-40 cartridge giving a 200gr JSP between 1,400 and 1,830fps (Sharpe 1937). IMR-4227 was superior and 29gr gave the 200gr JSP 1,890fps. No pressures listed for those loads but notes recommended by Dupont and we can assume a bit on the high side. 

 Lyman's 49th lists a max load, 17gr of IMR-4227 with a Lyman 427098. They claim 1,083fps with no pressure listed for Group I rifles like the Winchester 73'. I tested 17gr in my 20" MGM barrel I used for high pressure testing. 17gr with a 427098 resulted in 1,127fps (closely replicating modern Winchester Super-X ammo velocity) @ 9,500psi. I tested 20gr with a 43-215C (427098 replica) resulted in 1,418fps @ 16,500psi but also included .5cc of PSB shot buffer to keep the powder at the back of the case. IMR-4227 is position sensitive and could be why some of my early velocity tests were lower than the manual.

​Lyman's 49th handloading manual shows a max load of 18.5gr of IMR-4227 with a Speer JHP@ 1,212fps. This load only gave me 1,097fps. 20gr of IMR-4227 produced 1,297fps but also created 12,000psi, just a tad over the 11,000psi max. A caseload (26gr) of IMR-4227 with the popular Magma type 200gr lead bullet resulted in 1,733fps but produced 20,913psi....only safe for Group II rifles like the Winchester 92/94 and Marlin's 1894. I am getting consistent 10 shot 4" groups at 100 yards.

On a side note, IMR-4227 was a direct replacement for IMR-1204

The below information will conclude that pistol powders are not great for rifles shooting long distances. Lightly loaded Magnum powders work well out to 100 yards but if your desire is to shoot further, using a flatter trajectory...and retaining energy, a heavier higher pressure load is needed for a desired tighter group. Winchester already accomplished this with their High Velocity loads by 1903 and again by 1910. 

• IMR 4227

• Reloder 7

• Unique

• Trail Boss

• Bullseye - not yet documented by the author

It is my belief that Dupont manufactured the first smokeless powder used by Winchester in the 44-40. John Kort dissected several cartridges and found what he thought was Dupont No.2. He experimented with this powder, about April 2013, which he discovered to be as advertised by replicating such loads. Directly replacing black powder per volume, 17gr of Dupont No.2 was a "BULK" powder for the 44-40, produced 1,300fps but pressures are unknown to me. Looking at published loads in the 1930's, the 44-40 rifle loads that replicate 1,300fps show 10,000cup with certain powders like 2400 and Unique and possibly Sharpshooter and Lightning powders using the 200gr JSP. It has been reported that today's IMR-4227 has the same burn rate but yet 17gr (less volume) only produces 1,127fps @ 10,643psi (12,500cup). My tests using 19gr of IMR-4227 gave me 1,296fps with a 427098 @ 11,000psi (13,000cup) better replicating early smokeless powder loads in both velocity and chamber pressures. Better yet, 22gr with a Winchester JSP (.4255") gave 1,386fps @ 12,035psi (14,000cup) which is spot-on with historic smokeless powder pressures at those velocities.

What I believe to be the second powder used by Winchester was Laflin & Rand's "Sharpshooter" or at least Dupont's "Sharpshooter" by 1903. Both powders were perforated disc or very thinly sliced tube powder. Although a "bulky" powder, it was not a bulk powder but was also specifically advertised as a black powder replacement and noted as such on the powder cans "For Black Powder Rifles". Ironically 19gr of Dupont and Hercules Sharpshooter, by 1914, was noted as a High Velocity load. Sharpe's 1937 handloading manual notes 19.6gr of Sharpshooter produced 20,000cup. However, Sharpe also notes that 17.3gr of Sharpshooter (1937) with the JSP produced 1,305fps(normal factory velocity) @ 14,000cup (maybe 12,000psi) and 14gr producing 1,260fps but does not list pressures but would certainly be less than 14,000cup. It has been said the 2400 has a similar burn rate. If so, Lyman's 49th lists 18gr of 2400 with a Speer 200gr SJHP (#4425) @ 1,380fps and 14,600cup. 20gr of 2400 with a Speer 200gr SJHP #4425 @ 1,638fps and 19,000cup. My results differed as expected showing 1,300fps with only 16gr @ 9,000psi (maybe 11,000cup) and 1,672fps with 20gr of 2400 @ 15,618psi (maybe 18,000cup).

My testings with Trail Boss

Published 6.4gr max with an Acme Magma bullet produced 900-1000fps @ 7,224psi with great plinking accuracy but also did well out to 200 yards but may not retain enough energy for harvesting game.

However, a caseload were the bullet sits on top of the powder like black powder, held 9.3gr. This load gave me 1,250fps but at a cost of 15,182psi which could be close to 18,000cup.

Thus the burn rate vs velocity doesn't match very well when comparing Trail Boss to early Dupont bulk powders or even later bulky powders used for high velocity loads.

In 1913, Dupont introduced SR80 (Sporting Rifle). It was a granular type powder. similar in appearance to Dupont No.2 smokeless powder but was faster burning and was not a "bulk" type powder. It's burning rate was in the same range as Sharpshooter. Sharpe's 1937 does not list chamber pressures for this powder.

“Sharpshooter” and "SR80" fueled millions of .44-40 smokeless factory cartridges up until at least the 1950’s (SR80 was discontinued in 1939) when ball powders began appearing on the scene. Winchester switched to a ball powder similar to the old W630 which also has a similar burning rate to 2400. Remington continued to use “Sharpshooter”. I recently dissected some Winchester Super X cartridges and discovered the same type ball powder with a 12.8gr charge. Winchester last offered this load in 1978, then in 1979 Winchester began using a flake shaped pistol powder (similar to Unique) of which I weighed at 8gr. This is when the advertised velocity dropped from 1,310fps down to 1,190fps.

My "go-to" powders that seem to equally replicate velocity and pressures and most importantly accuracy are;

• 25.8gr of Reloader 7 with a 220gr lead bullet @ 1,361pfs and 12,000psi (est. 14,000cup). Factory standard velocity loads. (1894-1978)

• 24gr of IMR-4227 with a 200gr JSP @ 1,590fps and 18,000psi (est. 22,000cup). Factory standard High Velocity loads. (1903-1938)

These are the only two powders that give the greatest accuracy, retain energy (out to 200 yards and greater) and produce the least pressures in my tests.

Overview

Dupont No.2 vs IMR-4227

• 17gr of Dupont No.2 "BULK" powder produced 1,300fps but pressures are unknown

• 17gr of IMR-4227 (less volume) produces 1,127fps @ 10,643psi (12,500cup)

• 22gr of IMR-4227 with a Winchester JSP (.4255") gave 1,386fps @ 12,035psi (14,000cup)

No Data

• 17gr of Laflin & Rand's Smokeless Sporting Rifle Powder - no data found

Sharpshooter vs 2400

• 14gr of Sharpshooter (1937) with a 200gr JSP produced 1,260fps no pressures listed but would certainly be less than 14,000cup

• 17.3gr of Sharpshooter (1937) with the JSP produced 1,305fps(normal factory velocity) @ 14,000cup (maybe 12,000psi) 

• 19gr of Dupont and Hercules Sharpshooter (1903-1914) was noted as a High Velocity load @ 20,000cup. 

• 16gr of 2400 with a Speer 200gr SJHP #4425 @ 1,300fp @ 9,000psi (maybe 11,000cup) 

• 18gr of 2400, according to Lyman 49th, with a Speer 200gr SJHP (#4425) @ 1,380fps and 14,600cup

• 20gr of 2400 with a Speer 200gr JSHP #4425 @ 1,672fps @ 15,618psi (maybe 18,000cup).