Although the Super Redhawk was commonly chambered for six .44 magnum rounds, designing a six-shot cylinder for the larger caliber Casull round meant a cylinder with thinner cross sections between cylinder chambers. In addition to the Casull’s larger diameter, the pressures the thinner cross sections would have to contain were significantly higher. A standard .44 magnum round produces chamber pressures of approximately 42,000 psi when fired. The .454 round produces pressures of about 62,000 psi, almost 50% more pressure. Consistent with the difference in power, the .454 round has about 54% more recoil than the .44 magnum.
Ruger first tried making the cylinder from its traditional cylinder material, type 410 stainless steel. This material, a hardenable martensitic alloy, is generally considered suitable for highly stressed parts. However, this grade would not hold up for any extended length of time during test firing of the higher pressure proof rounds required for the Casull.