It's fairly easy (though time consuming) to reload a handful of shotgun shells with black powder loads for an old gun noidurism, even without shotshell reloading tools.
I've done it by hand with just a small steel rod to punch out the old primer, gently tapped in a new primer with a wood block and hammer, dumped in about 80 grains of black powder, seated a shot cup or wad with a wood dowel, added an equal amount of shot, and folded the crimp by hand and sealed it with candle wax.
The question is, why won't the shells made now fit it? You didn't say what gauge the gun is. It could be that the gun is a 16 GA and you tried fitting 12 GA shells in it. You might try Googling shotgun forums to get more help.
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My wife says I'm totally nuts, but I think I'm Semisane.
Things I've Learned:
(1) It's not possible to please everyone, but quite easy to piss everyone off.
(2) If you love animals as I do, then you're not a vegetarian.
(3) There's no need to act stupid, even if you're very good at it.
(4) If you eat right and exercise, don't smoke or drink, you're going to die anyway.
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