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If you use a swaged bullet, keep the velocities down...1000fps would be a max.
Cast is an excellent idea, but a commercial cast needs to be loaded up. I don't know what gun you're using, but 1200+fps from a 6" barrel would be a good idea. If you want to load somewhere between the two, you may have to get hold of one of the commercial casters that will customize the alloy.
I shoot my 6" M57 S&W a lot with an RCBS 210gr SWC with an alloy of WW+2%tin and 7gr-8gr/Unique with whatever standard LP primer happens to be handy.
This is probably the most popular .41 load today. I also shoot a large number of other loads that perform the same, and I'll give you some ideas if you don't have Unique on your bench.
The BB is to start seating easier, not for GCs. Gas check bullets don't need GCs, but usually smoke a bit because lube fills the space where the GC goes. I've removed the bevel in my molds so I don't have the problems they cause.Gas checks just make the bullets more expensive.
Have fun,
Gene
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