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I've been doing a bit of research on the methods of dealing with the lead fouling that results from shooting cast bullets. As one who doesn't cast them myself, I'm fairly limited to what variables I control, (i.e. BHN, lube, etc). So, I can't simply size the bullet according to chamber/throat dimensions to alleviate improper fit issues.
So, my question is: what's the trick to shooting manufactured cast bullets without excessive fouling?
I'm sure there's plenty of guys on here who have went through the same scenario-
1) Buy cast bullets for firearm because they're cheap
2) Load and shoot cheap cast bullets
3) Scratch your head for 10 minutes at the range because your barrel is clogged full of lead
What ya got guys?
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Let me see if I can wrap our heads around what you posted here,
1) So, I can't simply size the bullet according to chamber/throat dimensions to alleviate improper fit issues.
To a point you can, if you REALLY want to shoot those particular bullets. It might take a little work on your part and a few bucks for the components but it CAN be done realitivly easy. It would simple require you to pick up a Lee szing die, and modify it so that you could use it as a bump up die instead. This would alloy you to set the amount of bump up by how much is screwed into the top of your press, and then when you raise the ram it will squash the bullet out just a bit to fit the new diameter of the sizing die. Don't know how involved tapping out the top of one is, but somewhere I did see one with a nicly installed bolt screwed into it with a lock ring for adjustment. It was used to swedge the bullets out a few thousands and then they were run through the proper sizer for a better fit. That is only one option. It would work great is all your needing is say .003 in diameter or less you could probably get by with not even sizing after the swedge.
2) Load and shoot cheap cast bullets
This is somehat a get what you pay for area here. Some are less expensive than others and some ARE flat out cheap. If you slug your bore or have it slugged, you will know just where to start with on size. That is half the battle. Look for sizes that are around .002" bigger than where it slugs and you should be good. If running the 9mm look for a BHN of between 12 and 15 and you should be good there as well. Use the lower for lighter loads and the higher for heavier loads.
If you have the fit, the lube will be next. Plenty of casting companies use a harder lube as mentioned. However this doesn't mean it is all bad. If you can ask about their lubes find out what it is and who's it is. I know there is a lot of good talk about one of the blue lubes, and I know for a fact that if it is White Label Carnuba Red or BAC it is good stuff. Also if you are concerned with the lube being the culprit, like mentioned a bottle of the Lee Alox will do wonders to help correct that part as well.
As for scratchin my head over a barrel full of lead, yep been there done that. Loading lead is a comprimise no two ways about it. You either have to have the lead up to the loads level of pressure or get the pressure suitable for the lead. Either way, you have to have proper size and lube as well to even get to that point. The saying fit is king and lube is queen doesn't go together just because, it is a must. Once you have that the rest comes pretty easy.