Mostly Long Guns

To fully understand the significance of the Rossi R92 lever-action carbine chambered in 454 Casull, we must first examine the cartridge. During the 1950s, while being employed by the notable Gunsmith P.O. Ackley, young experimenter Dick Casull converted a Colt Single Action Army to a five-shot 45 Colt cylinder to increase strength. His unusual (and very heavy) triplex handloads allowed him to push a 255-grain bullet to 1,550 feet per second (fps), which was over-the-top power at that time. Dick referred to his handload and custom Colt as the 454 Casull. However, to achieve the level of power that he really wanted, a gun with a larger frame would be required.

In 1957, Casull started with a block of 4140 steel and sculptured a prototype single-action five-shot revolver that would house a lengthened 45 Colt case. He was able to push a 235-grain bullet to more than 2,100 fps. But it would take 26 years, filled with many challenges and obstacles, before the Freedom Arms Model 83 would be produced commercially. This revolver is remarkable, as it boasts of very high quality. It was the first production revolver with line-bored chambers, it offers incredible strength due to its design, along with uniquely heat-treated 17-4 PH steel, very tight tolerances and a high level of precision accuracy. As a result, it easily handles a steady diet of full-house 454 Casull factory ammunition, which was formally adopted by the Sporting Arms and Ammunition Manufacturers’ Institute (SAAMI) in 1997 and has a maximum average pressure (MAP) of 65,000 psi. This is higher than many modern high-intensity, bottleneck bolt-action rifle cartridges such as the 243 Winchester at 60,000 pounds per square inch (psi), the 7mm Remington Magnum at 61,000 psi, the 300 Winchester Magnum at 64,000 psi and many others.

Here is where it gets really interesting. Proof loads for the 454 are SAAMI specified at an amazing 130 to 140 percent above MAP, which results in pressures exceeding 90,000 psi. These “blue pill” loads are fired in every new gun by the manufacturer, to assure that it will handle SAAMI specification ammunition without danger to the shooter and there are no unseen metallurgical flaws. The impulse time is roughly 1⁄3 of the above named rifle cartridges. The combination of high pressure and a short or quick impulse time, makes it very hard to house this cartridge in firearms that are not super strong. In fact, the massive Ruger Super Redhawk 454 was the first Ruger firearm that failed proof loads. They had to re-engineer steel and other technical items to get the gun to withstand proof loads. In lever-action rifles, there was literally nothing strong enough to house the 454 Casull (at least at that time). During the 1980s, several experiments were conducted with both Marlin and Winchester leverguns, but neither offered the proper level of strength.

Shortly after the 454 was introduced and accepted by SAAMI in 1997, Legacy Sports International began working with Brazilian manufacturers to develop a Winchester Model 1892-pattern rifle that would house that cartridge. For the above reasons, this was not an easy task. However, the 1892 design features twin vertical locking lugs that offer great strength, but special high-strength steels had to be employed in the receiver, bolt and locking lugs to obtain adequate strength, as well as other engineering changes. This gun is known as the Puma M92, and its production began in 2002.

The Puma M92 features the traditional three-position hammer and is fitted with a manual safety on top of the bolt that when engaged, prevents the hammer from contacting the firing pin. Another departure from the original Model 1892-pattern rifles, includes an inner and outer magazine tube, with the inner tube screwing into the outer tube and there is a loading port similar to 22 rimfire rifles. However, there is also the traditional loading gate on the right side of the receiver. So shooters can choose to load the rifle using either method. The screw-in magazine tube feature was developed due to the sharp, fast recoil produced by the 454 when chambered in a lightweight carbine, which was causing the tubes to loosen in prototype guns. The M92 is constructed of a proprietary stainless steel, fitted with a walnut stock and rubber recoil pad. Fiber-optic sights were an option that included a two-dot green rear and red front. It was offered in 16-, 18- and 20-inch barrel lengths and in carbine configuration (with two barrel bands).

Twenty years ago, I obtained a sample gun with a 20-inch barrel and reviewed it within these pages. In thumbing through my notes, between 500 and 600 rounds were fired including factory ammunition and handloads. With the exception of one factory load (that is no longer in production) the gun fed, fired and ejected cases flawlessly. It was accurate with most loads producing three-shot groups measuring 1.4 to 2 inches at 75 yards with the aid of sight black on the fiber-optic sights to sharpen the sight picture.

After reviewing the Puma M92, it was purchased and used as a reference gun to test a variety of ammunition. First, it was used to develop handloading data for Wolfe Publishing’s LoadData.com website. Then, a major ammunition company contacted me regarding three lot numbers of 454 Casull ammunition. The first two lot numbers were experimental and were to be evaluated for possible production, while the third lot number was slightly out-of-specification when compared to their standard production loads. The company wanted me to test and evaluate the experimental loads in both rifles and handguns, while the third lot number was fired at my leisure and the brass retained for handloading purposes.

In working through the above ammunition and LoadData.com handloads, the Puma M92 has shot more than 10,000 rounds, which is a true torture test! At this point, the gun was carefully examined and the headspace was checked. Despite Browning-designed Winchester-pattern leverguns having a reputation for developing excess headspace after extensive shooting, the headspace remains within specification. As can be seen in the accompanying table, accuracy was similar when compared to when the gun was new 20 years ago. The only real issue occurred at just over 5,000 rounds, when the dovetail installed front sight worked loose. The dovetail was tightened and the sight was reinstalled and it remains tight.

It is noteworthy that H.P. White Laboratory tested two Puma M92 rifles prior to it going into production, which were each fired with several thousand rounds of factory loads, plus proof loads that were 150 percent over loads. The M92s passed the tests with flying colors.

Legacy Sports International no longer imports the Puma M92. However, Rossi-USA currently imports exactly the same gun, which is known as the R92. All of the above comments regarding the Puma M92 apply to the Rossi R92, which is readily available, dealers can be located at rossiusa.com.

I would like to see Rossi offer an optional aperture rear sight and post-style front, which would serve to improve it for field use. The overall comfort and shooter fitment could be further improved with a Winchester-pattern, shotgun-style buttstock that would disperse recoil over a larger area of the shoulder.

The 454 Casull offers notable power in revolvers, but due to its heavy recoil and the size of some handguns, it’s not for everyone. However, the R92 can easily push a 300-grain jacketed bullet to more than 2,000 fps, which is faster than SAAMI specification 45-70 Government factory loads, and is capable of taking all North American game. The 454 offers enough power to have merit as a rifle cartridge and owning a handgun of the same caliber is not a prerequisite. Plus, as a bonus, the R92 will feed most roundnose and roundnose flatpoint profile 45 Colt ammunition. The R92 offers accuracy, durability, is lightweight and has an attractive manufacturer’s suggested retail price of $1,098.99.