Hi Dave,
Some of the early continental Gem and Millita types were nearer to 6.5 than 6.35 mm as you have found out.
I am spoilt in that I can use the Lanes Patent Bullet Expander on the skirts of .25 Marksman pellets that I use in my oversize bores and my recommendation is you make/obtain something similar. There are plenty of engineers within our hobby and I think there is a market for a replica Lanes Expander or simply a ball upon which skirts may be placed and expanded.
Any takers?
Kind regards,
John