I have an 1885 H&H 450 BPE 3 1/4, that I had the same problem with, as you are having with Hornady brass (note- Eley BPE rounds fit perfectly). Superior Ammunition(Larry-Sturgis South Dakota) couldn't get the nitro for blackpowder rounds to go in the chamber after all kinds of adjustments. The recommendation, have the chamber reemed out. One custom reemer made $160. I gave the reemer to the gunsmith (Les Pittman). I am happy, Superior Ammunition is happy, and Les Pittman is happy. End of problem.
Herb


"In my GSP I do trust"