Mike;
We should live closer as I share your question to a tee. Being new here myself and just beginning the learning curve of revolver loading, I have learned a bunch from others here about tuning my Blackhack Bisley 7.5 barrel 45C and like yours, have throated to .45225. if not opening the forcing cone too 11 degrees I suggest that as well. Both changes improved my revolvers accuracy quite a bit going from 3-4 inch targets to 2-inch and better @ 25yd tests.
As for finding the magic with cast bullets and, after trying several loads for my choosen velocity of (1000-1100 fps), and with heavier than standard bullets this may help your quest.
I just tried Mt. Balty Bullets made in Cody Wyo. and they are shooting very well at 25yds, holding inside 2 inches. The weights I bought are the Keith 260, (weight of 273) and the 270SAA (weight of 283+) on my scales. These bullets are BH-11 (as advertised) and also very close to that as measured on my Saeco tester. Weighing them out in groups I found them to be very close in weight, not enough difference to weight select any of them. IMO- these are high quality bullets and having cast rifle bullets for some 35 years, I feel very confidant in telling you this.
So far, I have loaded both bullets with 9 and 9.5-grains Unique with just a smidgen of leading with 9.5 that pushed out easily with tight patch, not a brush. Not enough lead to mention really and then after 40 rds or so fired of each weight. Once chronographed I will post here but as mi meter os broken it and needs fixing, well thats another story.
Another test envolved the 270SAA bullet with 19 grains of H-110 just to check both leading and accuracy. Results were about the same, good grouping and mimimal leading after three cylinders full fired. As I'm about out of these bullets I will order more, at least 500 270SAA this time, maybe more.
Another test I like so far is my neighbors loads using the Cast Performance 300grain LBTGC bullets with this same 19 grains of H-110. These bullets are 22-BH and when fired, gave less felt recoil than the Unique loads, more of a push IMO- Accuracy is equal to the others and something I'll try more of for sure. My goal is for hunting deer and smallish Black Bears inside 50yds so don't want the big blaster loads my Ruger can deliver, rather something controlable to shoot off-hand with accuracy, and enough power to do the job.
At first, I thought the softer bullets would be my best choice for intended velocity but more tests will be made before choosing one. Hard bullets can be brittle I'm told but as I know so little here, more tests for that are needed if planning to use hard cast.
As for leading; I read somewhere that soft bullets, if shot to fast, will lead a barrel and hard bullets, if shot to slow, will also lead a barrel. My neighbors loads, he says, never give leading issues and perhaps due to the gas checks. He says they penitrate completly through deer at 50-60 yds going end to end on one big bodied 3-point buck shot about 35 or 40 yds. To date, he has made 6, one shot kills with his Ruger BH and Cast Performance bullets, all fired at 19 grains of H-110 and 350CCI primers.
ADD on: what forzone said makes tons of sense to me; thanks for posting that!
Keep us updated on your progress please.
GC45