I have a Badger barrel that has the following data marked on the bottom barrel flat.
"Badger 16 TW .4085 GR"

Can I assume that it takes a .410-.411" bullet?

thanks,

Rich

That will depend on your chamber... - and what the barrel likes best, of course!

The bullet should come from the mold very close to groove diameter.

I've never been able to improve accuracy by sizing bullets down.

If the groove diameter is .4085 I could get a .407 to .4095 bullet to shoot accurate.

If the chamber neck area is to small in diameter you can either open it up with a neck reamer or try smaller, softer bullets. If you want to shoot oversize bullets like .411 through a .4085 barrel you might want to neck ream and cut a long taper in the throat.

Using the correct size bullet seems a lot easier to me.
But then, you could size the bullets down and then swedge them back into shape with a bullet swedge.

You want a mold that casts a .408 bullet.  Simple.    Wait a minute!!!

Straight or tapered bullet??  Oh man!   Now we have to start all over again.  

No, no . Use a tapered bullet. They shoot better than straight bullets.

Wait a minute!  You shootin BP or the much superior smokeless powder?  

Just kiddin! Doesnt matter. Yuk yuk.    

      Joe.  

Agree with Mb better if the mold drops near the correct diameter but heavily sized bullets can shoot, just not as well as "as cast"

Boats

reading between the lines, I think I am going to be calling PJ or Steve Brooks for a new mould.  Oh well, it's only money...

Rich