Thanks for all the replies.
I have been reading a lot from CastBoolits.com, and the book that Grumpyold mentioned, From Ingot To Target.
LOTS of info there!
One point they make is that correct sizing is FAR more important than hardness. Yomomma hinted at that.
So now I am thinking that instead of segregating my WW from my mystery mix lead (mostly pure lead pellets, range scrap, and some dentist office Xray shielding), I'll blend it all together and not try to hit 30+BHN
Howard2, I'll look for JR Mattern Handloading Ammunition. That is new to me.
Amosfella, I havent thought of PP. The 30-06 will be for my Garands, so the PP may get stripped offon the ride to the chamber.
Should be fine for my Lee-Enfield though.
Phishroy, that 2-alloy idea looks REALLY time consuming.
Loyalist, I was planning on waterdropping right after the PC cooking.
Keep your soft lead and ww lead segregated - sizing is likely very important but it is absolutely possible to be too soft as well. The best lead for high speed cast rifle shooting is at least BHN 14-16, and heat treated to about BHN 18-20. WW is somewhere in the 12-14 BHN area (it varies considerably) so if you mix it with pure lead you'll be dropping down well below optimum. WW are perfect, esp if you heat treat. Info on heat treating here:
http://www.lasc.us/heattreat.htm
Use good lube and pick bullets that have sufficient lube grooves - some bullets don't carry enough lube and are prone to leading at higher velocity. I have had good results with Red Dragon from Dragon Lube, the site sponsor.
You'll need a gas checked bullet for those speeds.
Antimony makes lead harder and tougher, tin makes lead flow better and more brittle. Learn the difference.
For 2500 fps there are going to be several variables in play that haven't been touched on yet that will also influence your success or lack of it. Powder selection, spin rate, peak pressure, alloy, bore condition are all part of the equation. At higher velocities I've had better results with slower powders than what would be optimum with a jacketed bullet.
High peak pressures tend to cause bullet shear and loss of accuracy = if you get to the point where your accuracy starts to drop off as velocity increases then you could be experiencing shear - this being caused by the bullets natural resistance to being spun from a non-spinning state, and insufficient strength to support the imparting of spin - basically the outside of the bullet starts to spin and interior doesn't keep up - so they part or "shear". If you push it hard enough you will eventually run into this. Slower powders with a lower peak pressure will help somewhat with preventing bullet shear in many cases. You know you have shear when your bore is leaded in the first inch.
2500 fps is do-able, but not with every bullet and not in every rifle. I'm got over 2300 fps out of 280gr cast in 9.3x57, and got over 2300 in 9.3x57 using the same bullet, all without leading. In the x57 the best accuracy was found about 1850 fps which also happily corresponds very well with the fixed open sights on that early Huqvarna rifle. In the 9.3x62 the best accuracy was about 2200-2300 fps and dropped off after that, with traces of shear at 2400 and lots of it at 2500 fps.
I'm working on a new 458 winmag and have test fired a few 485 gr cast bullets in the 2100 fps range with room for velocity increase. Need to do more shooting but so far accuracy is "promising", which means i haven't run into a wall yet - and that does happen with cast bullets.
30-06 and .308 are good cartridges for cast bullets and there is a lot of molds to choose from. HP bullets work at lower velocity but in my experience aren't so useful at rifle velocities. A flat meplat will work quite nicely on game. There is some expansion with bullets in the 18-20 BHN range, not so much when you get up to the 30 BHN range.