The Lee 230 grain truncated cone in tumble lube version would be a perfect compromise. Feeds great in a 1911 and you could crimp in the top lube groove for 45 colt. Plus that flat point can do some serious damage!
I've been casting range scrap for my 1911. Its pretty soft like around 10 bhn and I can go about 200 rounds before it needs a good cleaning. Leading isn't horrendous, just get a good lead remover like shooters choice and the barrel will be shiny again in no time. Also I dont own a thermometer...
Could some sort of oil or lube gooten into the primers or powder? It could be low pressure but that discoloration may be a hint of something else. 6 grains of bullseye should get a bullet out of the barrel.
A six cavity mold of tumble lube design so that sizing could be skipped would be the cheapest and fasted route. Set aside a nice evening a week and make a couple thousand bullets.
Grab that X-terminator! That's my favorite powder for .223 and 55 grain Hornady FMJ. It has a faster burn rate than TAC and many people haven't caught on to it yet. My AR-15 with a 1/9 twist loves that powder bullet combo. I can't remember the exact powder charge but it's close to the max...
I also second the theory of your barrel diameter being larger than your cylinder throats. Your cylinder is probably swaging your bullets to .357 and your barrel may be slightly larger. Time to find you a fishing sinker or a pure soft lead bullet and find your bore diameter. If it's larger...
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