No need to complicate things. Just prime the new brass, flare the mouth to accept the bullet, load, fire, smile, repeat. The only time I've run new 38-40 or 44-40 brass through a sizer die is if the mouth of the case was damaged. Oh, and I size all my cast bullets for my 44-40's .430". My old Uberti revolvers chambers will even accept .432" sized bullets.
CHT