Howdy
I am one of those guys who shoots one diameter bullet in different groove diameter rifles. At last count I have five rifles chambered for 44-40. An antique Marlin Model 1894, two antique Winchester Models 1892, an Uberti replica Winchester Model 1873 and an Uberti replica 1860 Henry.
I have slugged them all, groove diameters for these five rifles are either .427 or .429. Interestingly enough, one antique Winchester and the Henry have .429 barrels, the other antique Winchester, the Antique Marlin, and the Uberti 1873 all have .427 diameter barrels. Go figure.
When I stared out with the antique Winchester with the .427 barrel I was shooting .427 diameter bullets in it. I tried .427, .428, and .429. in that rifle. The same with the Uberti 1873. It turns out the chamber of the Uberti 1873 was tight enough that .429 bullets expanded the case mouth just enough to make the loaded rounds difficult to chamber. But I had no problem shooting hard cast lead .427, .428, or .429 bullets through those rifles, accuracy was fine. Yes, I have always read that cast bullet diameter should be .001 over groove diameter, but all three diameters shot fine in the .427 barrels and accuracy was fine. Again, go figure.
My CAS Main Match rifle for the last ten years has been the 1860 Henry with its .429 groove diameter. Not wanting to load 2 different diameters for different rifles, I settled on loading all my 44-40 ammo with .428 diameter bullets. Yes, .001 undersize for the Henry groove diameter. Accuracy is fine, no problem. Of course I shoot nothing but Black Powder in that rifle, and the very soft lead bullets I use may be bumping up in diameter in the barrel. I really don't know.
Whatever the case, I have been doing fine with .428 bullets in the .429 groove diameter of the Henry for about 10 years now.
Bottom line, with cast bullets, it really does not matter a hill of beans if the bullets are slightly undersize or slightly oversize. Maybe if I was trying to shoot hairs off a flea at 50 yards it would matter, but I don't require that kind of accuracy.