So, a factory .30 Luger barrel dropped in, other than the muzzle OD issue? How tough would it be to re-line a 9mm barrel to .30, instead? I thought the factory .30 slide was extensively lightened, compared to the 9? All those isssues aside, I have a 1920 Commercial Luger, and my load development procedure was identical to yours; I loaded up until the gun functioned, then added enough for a safety margin. I found my gun, loaded with 85-90 grain bullets, would function erratically until velocities got to 1100fps, then it ran perfectly. The groove diameter is .3095", so I've been running lubed .311"-312" bullets (85gr. Hornady XTP is my favorite) through a Lee .309" sizing die, and getting a perfect Luger bullet.
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