Howdy
The 38-40 cartridge is basically a necked down version of the 44-40. It was the second cartridge Winchester chambered the Model 1873 for in 1879. Colt first chambered the Single Acton Army for 38-40 in 1884.
This photo shows, left to right, 45 Colt, 44-40, and 38-40. Other than being necked down to 40 caliber (yes, 40, not 38) the 38-40 case shares all other major dimensions with the 44-40.
So far I have two firearms chambered for 38-40. This Winchester Model 1873 made in 1887.
And this Bisley Colt made in 1909 IIFC.
Use a little bit of caution about how much powder to put in the case. When I first loaded 38-40 I used the same amount of powder as I do in 44-40, 2.2CC. This worked fine with some storebought 38-40 bullets, but when I loaded up some Big Lube .401 diameter bullets they would not chamber in my Winchester. Turns out because there is slightly less volume inside the 38-40 case, the extra compression of the load was squashing the dead soft, pure lead bullet slightly, and expanding its diameter. So the rounds would not chamber. I throttled back the load to 1.9CC and everything was fine.
Rather than filling the case to some arbitrary distance from the top, instead determine how much powder it will take to be compressed about 1/8" when you seat your bullet. This will of course vary with how deep any particular bullet sits when it is seated. This is easier than it sounds. Take your prospective bullet and line it up with the crimp groove even with the case mouth. Make a mark on the outside of the case even with the bottom of the bullet. Now make a little ruler from a small stick, with a mark on it the same distance as the mark on the case. Fill the case with enough powder so that the end of your little ruler is submerged about 1/8". That is your ideal amount of powder for that particular bullet. If you want to weigh it, go ahead and weigh it. If you have some sort of volumetric powder measure, set it to throw that amount. That's it. Fill the cases so the bullet compresses the powder by about 1/8" when seated.
I've said this a bazillion times, but I will say it again. Black Powder is not as corrosive as most folks think. In the old days, the combination of corrosive primers with BP fouling made for a lot of corrosion. We don't use corrosive primers any more, and the BP fouling by itself is not as corrosive as most folks think. Yes, you have to clean the guns, but you do not have to do it right away. I have a couple of antique revolvers staring at me right now that I shot with Black Powder last weekend. Yes, I need to clean them. When I do, I do not expect to find any corrosion.