Ten years ago I acquired a much-used 1894 Winchester .30-30 with shot out barrel. Factory loads keyholed and cast loads wouldn’t shoot acceptably.
In the 1980s Roy Dunlap showed me a .35/.30-30 Marquart built on a Remington 788 which worked well on the 500 meter rams for cast bullet silhouette shooting, so I thought a lever-action in this caliber would make sense. I sent my 1894 to John Taylor for relining because due to condition it had no collector value. I use .30-30 brass necked up to .35 cal. with no other change. John recommended relining instead of reboring, because the pre-war nickel steel Winchester barrels are difficult to get good interior finish on a rebore. Cost is about the same either way. Original markings and patina are preserved. John used a liner having 16-inch twist with rifling dimensions the same as for the .35 Remington.
I wanted a cast-bullet rifle which I would use common jacketed or cast bullets and common .30-30 brass which I have in abundance. The objective was to “split the difference” between the .32-40 and .38-55 Winchester. It does exactly that. A custom Redding die set easily necks up .30-30 brass to .35 in one pass. I can use either .375 Winchester, Starline .38-55 Winchester 2.085," .32 Winchester Special or .30-30 brass as feedstock.
There being no pressure tested load data for this wildcat, I measured water capacities of the .35 Remington and .35/.30-30 to see how close they were. Brass in both calibers was Winchester, the .35 Remington case was once-fired from a Marlin. Capacity in grains of water when filled to base of neck: .35 Remington - 39 grains; .35/.30-30 - 34 grains.
When a 200-grain jacketed .35 Remington bullet is seated in the .35/.30-30 case, its base is about 1/3 the way up the neck, so I took another measurement, this time filling the case neck with water and carefully squeezing out the excess pressing a bullet to the crimp groove in the fired case. That result was 37 grains.
I determined that using .35 Remington load data was OK as a guide as long as I stayed a grain or so below maximum loads. This has worked very well in practice. It works out that with a 200-grain jacketed .35 Remington bullet you can fill the case and compress the powder about 1/8" as if loading black powder, and that you cannot get enough powder in the case to get into trouble using IMR3031, IMR4895, IMR4064, RL15 or Varget.
The 16" twist stabilizes the Accurate 36-245D bullet subsonic. For a heavier hunting load I can load the same bullet with the nominal caseful of 4064, RL15 or Varget, filled "gently" to the base of the bullet with only slight compression about 32 grains, for about 1600 fps with no leading, game performance being much like a .38-55 Winchester. Overall cartridge length when .35 Remington 200-grain softpoints or Accurate 36-245D are crimped in their crimp groove using reformed .30-30 brass is 2.52-2.54", which feeds perfectly in the Winchester 94. Typical open-sight groups shot at 100 yards, hand-rested on my deck rail are about 4 inches for ten-shot strings.
With Accurate 36-245D 7.8 grains of Bullseye gave 1095 f.p.s. with an Sd of 18 over a 10-shot string. A charge of 16 grs. of #2400 gave 1421 f.p.s. with an Sd of 30 with only slight leading on the driving edges of the lands. Reducing the charge slightly to 15.4 grs. of #2400 gave 1383 f.p.s., with round open-sight, 4-inch groups at 100 yards without leading. Who could ask for anything more?
200-grain Cast Plainbase Accurate 36-193A 1:40 Alloy
7.2 grs. of Bullseye 1050 f.p.s. - Sd 37, necks smoky. DO NOT REDUCE
7.8 grs. of Bullseye 1250 f.p.s. - Sd 19, clean shooting hot weather load
8.4 grs. of Bullseye 1313 f.p.s. - Sd 11, Max. useable without any leading
9.0 grs. of Bullseye 1371 f.p.s. - Sd 17, Some leading. DO NOT EXCEED, approximates .38-55 black powder velocity.
Ballistic uniformity with Bullseye is not acceptable below 1000 f.p.s. I don't use any case filler and make no attempt to orient powder charge, but just shove 'em past the loading gate, lever them into the chamber and bang them off. About 4 inches at 100 yards is typical for an open sighted 94.
Winchester LP primers showed no pressure signs with any of the loads and didn’t flatten.