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Unddersized bullets in a .38 Special conversion aren't uncommon. Your solution is either heel based bullets (think about a .22LR and the way it's designed) or you can use soft leaf bullets with a hollow base. I have 3 Remington Navy conversions and this was my solution and it works pretty well. The hollow base acts like a minie-ball expanding when it's fired so the bullet fills the bore.
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