Here is a post I made back in 2008.
I have an early field grade .454 that I bought about 20 years ago. I struggled with it off and on over the years due to what I thought was tight throats. FA Factory 300gr ammo had to be forced the last bit into the chambers with heavy finger pressure. A year ago (yeah, I have a high tolerance for pain -- actually just lazy) I needed some work done to my M97 and mentioned the tight throats on the .454 to John at FA. He had me send the .454 cyl in along with the 97. When it came back the tight throat problem was fixed. The original throats were extremely abrupt (no chamfer/taper at the rear of the throat). From what I remember, FA chamfered/tapered the lead into the throats, but didn't open them up. The throats will let a .452 bullet pass but not a .453, so call them .4525. We slugged the bore, and it is right at .453.
So, my first suggestion is to see if a .452 jacketed bullet will pass thru the cyl throats from the rear of the cylinder. If not, see if they will pass thru from the face of the cylinder – if they do, you may have the same problem that I had. If not, you’ll probably have to use .451" bullets just so they will chamber.
In my experience with the FA 475 LB (and the fixed .454), any of the Keith SWCs with the wide front drive band above cyl throat diameter are virtually impossible to seat in tight throated cyls. The LBT WFN with the longer (relative to a shorter nose in same caliber) nose to crimp measurement can also be difficult to seat. The WFNs from Cast Performance, as well as some of Leadhead’s bullets seem to be dual diameter – the base will be larger than the portion of the bullet in front of the crimp grove – so no seating problems. LFNs, and RFNs seem to be less prone to sizing/chambering problems. Unfortunately, about the only way you are going to figure it out is to actually try different nose profiles, manufacturers and diameters.
My gun has a six inch barrel and is the most accurate handgun I have ever owned or shot.
Paul