If you want to load BP use paper wads from
www.circlefly.com - plastic wads will melt in the barrel and be bad to clean. For 10 years or so I've used a Mec [ 600jr, 650, or Grabber ] to load BP. Don't understand how you get a spark with a aluminum charge bar - anyways, I've never had a problem. A 46A bushing will throw 75grs. Cut one in half and get 84grs, or no bushing and get 95 grains. I've been shooting 10 or so damascus guns for about 10 years with both smoke and smokeless. For nitro I've kept my loads around 5500 to 6500psi - there are many loads out there at 1150fps with 3/4oz to 1 oz. And I believe Sherman Bell proved there's not much pressure increase by useing 2 3/4" shells in a 2 1/2" gun. If you're only at say 6000psi the pressure wouldn't go above 7000psi, if that. Good luck - Paul