Unless you elect to send the rifle to someone who knows what they are doing, your best bet is to bite the bullet and send it back to Rossi. They may be slow but that is a whole lot better than using your face and eyes to stop shrapnel brass. Be sure and include the blown case in your shipment to Rossi. Don't include the new extractor.
So you ran into an Original Winchester 87 with an Out of Spec chamber. On the other hand, I have been shooting this same pile of Brass Hulls in 6 different double guns with nary a problem. For myself and perhaps others, the CH4D is a $400 solution to a problem that may well not need a solution.
HEY DEACON !!
When "Wild Bunch" was young and first established as a fun side match, BEFORE SASS screwed it up, we could come out and play with ALL of those fun Safe Queens. 1917s, Broomhandles, Lugers, Colt 1909. Then SASS got hold of it and turned it into CAS with a 1911. Phooey
Actually, unless you're doing something strange, you may well NEVER need to resize Brass Hulls. I've been shooting the the same pile of MagTech hulls for about 5 - 6 seasons and have only needed to resize three hulls. At was cuz some ham hock stepped on 'em. I also DO NOT recommend a crimp on yer brass hulls.
Who says 44-40s-R better-n .45s??? Just WHO. WHO WHO WHO let the dogs out anyways. .45s-r-Us you betcha.
Not gonna fall for that again neither!! Crab Cakes. No way, No Frosting!! Fooey-n-humpf, crab cakes indeed.
I worked on a number of 1866s and Henrys that were completely clapped out. Trigger Spring and Hammer were just fine. The usual culprit was the wear of the Trigger Sear. My first look would be the Trigger. the next worse wear point, as mentioned by Slim is the thru bore for the Extension Rod. Parts have already been ordered so best of luck.