Casem4 said:
The issue is my gun is a fast twist and is a shallow groove gun. It is not designed for patch and ball. ... I did measure my casted real and it is about 1/10 off of the correct size meaning there is space from the shallow riffling.
The largest band on your REAL bullet should measure 0.517". If the diameter of your home cast REAL bullets results in a 0.100" undersized bullet, there must be something in your lead pot that is causing all that shrinkage. I suspect your casting metal. Since the ball is that much undersized, it will not engrave on any rifling regardless of depth. For your bullets you are effectively shooting a smoothbore. When you get your 2fg black powder, but some 50 caliber bullets at your local gun shop. Measure the diameter of those bullets as compared to you home cast bullets. Let us know the measurement of those bullets. If you have a scale, weigh the bullets. What is the weight of your home cast REAL bullets. They should be very close to 320 grains.
On your targets at 25 yards, do you have any observable tumbling? Once your 50" of snow gets off the ground you need to go to the range. Use this process.
1: Really clean your rifle. Use a brush and solvent such as break cleaner to get rid of that baked in Bore Butter. Use a pipe cleaner to clean the flash channel between the nipple seat and the powder chamber. This process requires a very clean rifle and bore.
2. Shoot a 3 to 5 shot group at your 25 yard target and record the bullet, bullet lubricant and weight of powder and powder type and granulation. Is that the same group you got on your earlier range trips?
3. With the same load shoot 3 shots at 30 yards. What does that target look like. Is there any evidence of bullet tumbling? Record in you notes the difference between point of aim and point of impact.
4. With the same load, shoot a 3 shot target 5 yards further out until the group opens up. Look for oblong holes that might indicate tumbling. Record your results.
5. Using the new store bought bullets, shoot the 3 shot group at the range that the groups are opening up. Record the results.
6. Report all your results back to us. With pictures if you can post them.
At this time I am speculating that you have a contaminated lead supply and the bullets are shrinking way too much in your mold. There may be issues with the accuracy of your caliper. There may be so much caked on Bore Butter that your rifling can't properly engage the Lee REAL bullet.
Keep your hands away from the file until you are getting good groups.