I'd love to shoot BP only, but it's my understanding that shooting .45 BP loads through a lever gun without fouling the works is pretty tricky. I've read several articles on how to make it work, and it seems a bit more trouble than it's worth. (At least for a novice like me.) Which is why I'm set on getting a a set of guns chambered for .44-40, but shooting smokeless in my .45's until then.
Howdy
Generally speaking, guys who talk about how much Black Powder fouls up the mechanism of a rifle,
1. Don't shoot Black Powder in a rifle, and
2. Don't know what they are talking about.
A rifle, unlike a revolver, is a closed system. There is no barrel/cylinder gap for fouling to be blasted out all over the place. As far as fouling is concerned, a rifle is just a pipe. If you can seal the chamber well enough to avoid blowback, the fouling will all stay in the pipe and very little will get in the mechanism.
It's really very simple. To accomplish this, you need to seal the chamber as well as possible when the rifle fires. In order to seal the chamber you need to generate as much pressure as possible to expand the brass. This will eliminate gas from blowing by the round in the chamber and and fouling up the mechanism. This gets right back to what Trailrider is talking about with generating pressure. It also gets back to choice of caliber, and in a smaller way it gets down to the model of rifle you choose. 44-40 is perfect for shooting Black Powder in a rifle. 44-40 brass is thinner at the neck than most other calibers. Only about .007 thick, vs about .012 thick for 45 Colt. So with any given amount of pressure, the thinner 44-40 brass will expand more efficiently and seal the chamber than a similar load in 45 Colt will. Of course, you do have to develop some pressure and if you start fooling around with light loads, and fillers, you are defeating the entire purpose. I shoot nothing but Black Powder loads in CAS, my rifles are all 44-40, currently I shoot a Henry but for a number of years I also shot a '73. I stuff the case full of powder and plop a soft lead Big Lube bullet on top. When my rounds eject, they seal the chamber so well that they are as clean as Smokeless rounds. No fouling gets into the mechanism.
45 Colt can be a little bit more troublesome, because of the thicker case. Most guys who shoot 45 Colt Black Powder loads in a rifle do get some blowby resulting in some fouling in the mechanism. Again, by filling the case with powder, using a heavy 250 grain bullet, and a firm crimp, this can be mostly eliminated. Even with a little bit of fouling in the mechanism, it is usually not a show stopper and a little bit of a squirt of your favorite Black Powder solvent will keep a gun running through a match.
Too a lesser extent, the rifle model will also have some effect on fouling in the mechanism. All the toggle link rifles, the Henry, Winchester Model 1866 and Winchester Model 1873, have the mechanism physically removed from the carrier. The carrier is in front of the rest of the mechanism. That is why their frames are so long. With this arrangement, any fouling that gets past the chamber will usually stay in the area of the carrier, where it can easily be dealt with. The more modern designs like the Winchester Model 1892 and the Marlin Model 1894 are more compact. They are more wide open with the carrier in the same location as the rest of the mechanism. So any fouling that manages to get by the chamber will probably get into the mechanism. Again, no big problem at a match, with a judicious squirt of solvent. At cleaning time, the Marlin has it over the '92 because takedown is very simple and the entire action can easily be cleaned out. Takedown is a bit more fussy with a '92. With a toggle link rifle, I don't even bother to disassemble it for cleaning. A few swipes of a bore snake through the bore and the barrel is clean. A little light application of solvent to the accessible areas of the action and I am done. I only take them completely apart to completely clean them out once a year.