I HAD the same problem with my original 1892, using Rel 7 Max loads.
Even factory loads were a bit dirty.
I learned that the action will with carefull load development take quite a bit more pressure. When the pressure increases, the case seals the gas nicely. The sudden pressure spike of Black powder works well here too.
Using a heavier bullet, or changing to a faster powder may also be a cure.
Remember, you are venturing into territory that the data lawyers will not like.
Be very very carefull.
This load worked very well for me. Now I must put in a very big
WARNING!
This load came from no loading manual, it is my own contrivance, it was developed by extrapolating data from other cartridges of similar case capacity, and is quite likely DOUBLE SAAMI PRESSURE SPECS.
I have limited experience with it so far, and have not checked it for accuracy, or chronographed it.
DO NOT USE IT IN A HANDGUN OR WEAK ACTION RIFLE!
Work up to it carefully in any other!
Pressure sign on low pressure cartridges is very difficult to read, and develops rapidly, go slow.
Winchester once fired case (38-40), 174 grain hard cast bullet, Winchester LR Primer, 23grains H110.
Note on H110. If you start very low, you may get hang fires, and misfires, and bullets lodged in the bore. H110 likes it hot.
REGARDLESS
BE CAREFULL, start low, go slow!
Hogdon does not support this load, and probably will warn sternly against it!