rohk-
I poked around in my basement archives a bit looking for information on reloading the 32-40. I found some loads, and learned a couple of things. I suspect you already are aware of them, but I'll put them here just in case a novice Ballard owner finds this thread.
A really helpful book is
Handloading by William C. Davis, published by the NRA. Some of the articles included are a graduate course in handloading. The section on the 32-40 included some information specific to loading the Ballard and Stevens: Here's a quote:
- As with some other blackpowder cartridges that existed during the transition to smokeless powder, the .32-40 was for some time produced in a special "high velocity" smokeless load, developing substantailly more chamber pressure than the blackpowder load. Such loads were intended for use only in the stronger guns, such as the Winchester 1894, Marlin 1893, Savage 1899, Winchester Single-Shot, and Stevens 44-1/2. They should not be used in the weaker blackpowder guns such as the Ballard or Stevens Model 44 single-shots. The normal working pressure for .32-40 ammunition when it was last loaded by U.S. factories was about 30,000 c.u.p. That is undoubtedly satisfactory for the stronger actions mentioned above, but for the old Ballards and similar actions, it would be inadvisable to exceed the ballistics of blackpowder loads.
I suspect the blackpowder pressures did not exceed about 20,000 c.u.p. Using QuickLoad to find low pressure loads could be a useful exercise. The book lists four loads running about 1100-1400 fps with 165-175 grain bullet with Unique, 2400, and 4227 that they recommend for the Ballard and Stevens.
Some of the older Lyman handbooks, (Number 43 and earlier) list cast bullet loads that are likely suitable for the Ballard.
You might ask your question in a forum over at assra.com.
Be careful!
--Bob