I am not an expert on BPCR rifles, by anyone's definition, but I'll offer what I know. The question of bullet diameter has been addressed pretty well by the above posts. Slugging your bore is a necessity, there is no other way to know what diameter you need. The rifle will not shoot to it's potential without proper fitting bullets. Attaining that ideal, though, is no piece of cake. As cast bullet diameters will vary a small amount in any given mold, with changes in alloy, for example. I do not have a lot of experience casting bullets for BPCR, but I have been dicking around for a year and a half with conical bullets for my muzzle loading Gibbs rifle. In the end, I have made sizing dies for both paper patched and grease grooved bullets, because that was the only way I could get a perfect fit.
Bullet weight is less a matter of preference than a matter of science. The twist rate of your bore requires that you use a bullet that is of proper length for that twist rate. For example, a 1/18" twist rate will stabilise a longer bullet than a 1/28" twist rate. My experience is with .45 cal, so I will use examples. A typical 45/70 has a 1/18 twist rate, and needs a 540 grain (more or less) bullet to stabilise. This is not because of the weight, but because of the bullet length. A .45 cal, 540 grain bullet will be about 1.4 inches in length, more or less. A 45/90 WCF, OTOH, is an "express" cartridge, meaning that it was designed to shoot a lighter, shorter bullet, at higher velocities, than the 45/70. In order to stabilise the shorter bullet, though, the 1886 Winchester rifle has a twist rate of 1/28". It will not stabilise the much longer 540 grain bullet. It requires a bullet weight of about 300-350 grains, in order to get the proper length.
Another question is what alloy to cast with. The bullets need to be hard enough to maintain its shape, but soft enough to grip the rifling easily, and to "mushroom" if you shoot a deer with it. You need to consider whether you want to use paper patched bullets, or grease grooved. You need one or the other, to prevent lead fouling. Alloy hardness will also play a roll in lead fouling. If you choose paper patched bullets, the bullet diameter will have to be smaller by .004", or so, to allow for the patch.
As you may notice, the question of bullet selection for a BPCR is not real straight forward. OTOH, it is all based on physics, so while the requirements seem complex, a little research will get you pretty close. Each rifle is an individual, but the physics are pretty constant, so apart from minor tweeking, most of the variables are predetermined by the bore diameter and twist rate. That said, these things will drive you to drugs! Check out
http://www.bpcr.net/site_docs-results_schedules/documents/bp_cartridge_reloading_dick_trenk.htm, or
http://www.bpcr.net/forum/.
Oh, almost forgot, check out
http://www.boomersmoulds.com/index.html, if you can't find a mold that you like. Leo makes custom molds for a reasonable sum, in Regina, SK.
Good luck with your project. Hopefully, one or two of the real experts on this forum will chip in and give better information than what I have.