Yep, casting is really a tinker's game!
I have managed to match jacketed velocities with my .308Win. (200gr. #311299)
I have to clean it every 10 rounds or so to maintain 3.5" ish or less groups at 200 yards. The bore doesnt appear to be leading significantly, but just shoots better for the first 15-20rounds.
Yes these cast bullets CAN really shoot! It took me a long time to work up the loads and all the reloading particulars, but it came together.
One thing has become apparent to me. Twist rates, if slower (Such as 1:12" in .308, opposed to 1:10") seem to be able to reach higher velocities before accuracy starts to degrade at higher velocity levels.
I think the torque imparted to the bullets outer layer of alloy (during acceleration) is less affected in a slower twist rate. (at a given velocity)
My alloy has always been wheel weights + 8 feet of 50/50 Lead/Tin solder. Air cooled.
For maximum velocity loads for hunting, I like/tend to use much slower powders than what is "normally" used/reccommended for cast bullet shooting. (IMR4350 & IMR4831). I have fired close to 500 rounds with these powders, and they are perfectly safe in my rifle.
I also like to use IMR SR4759 for loads in the 1500-2000fps range. Past that velocity, my accuracy seems to suffer.
I use a dacron filler to take up the space between the top of the powder and the bottom of the bullet in ALL my loads that dont have at least 90%+ ish load density. The dacron does boost pressure/velocity by 25-30fps or so on average in the loads I tested. No big deal for sure.
I think it helps/aids to seal the expanding gasses behind the Gascheck, further enhancing the loads consistancy.
The loads that use filler have shown a definite trend to shoot smaller groups, and lower the Standard Deviation. CONSISTANTLY
The bullet is seated into the lands. And the bullet nose is coated with two layers of Lee Liquid allox. I feel this extra lube helps the bore riding (Lyman #311299) bullet, to hydraulicly hold near perfect center. At least that is my personal theory/feeling.
The bullet is sized to .310", and has a Hornady gascheck applied to the base.
Lyman Super Moly Lube is used in the bullet lube grooves.
Aluminum Gaschecks work great, but they tend to start failing (group wise) around 2200fps APPROXIMATELY.
This cast bullet shooting can create loads that take allot of work to assemble, but it is still fun for us shooters who like to tinker with fine details, and always try to improve.
Check out the "CAST BOOLETS" web site to learn huge amounts about cast bullets And Cast Bullet shooting.
I hope this information can help someone enjoy cast bullet shooting more!