How to load coated cast bullets?
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.45Coltguy
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I have also gotten better accuracy with coated bullets in .357 and .45 Colt. Whether in revolver or lever rifle. The only exception was 165gr rnfp coated in 30-30. But, I ran out of bullets to keep trying. Back to jacketed for that one.
Docendo Discimus
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crstrode
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A valid accuracy test would be to compare bullets made from the same batch of lead, from the same mold, cast at the same time. Lube some with traditional lube and some with "coating". Then shoot them under the same conditions, on the same day at the same target from the same distance, over the same load, in the same cases, from the same gun - properly and thoroughly cleaned before and after.
I doubt there will be any significant performance variation betwixt the two.
More likely a function of not being cured properly. If the instructions aren't followed correctly leading will result even with light .38 Special loads. I run coated bullets in 450 BM and .30-06 without issue.
mcb
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I have always loaded them treating them like a regular wax lube tradition lead bullet of similar shape. I have shot a heap of them in 38 Short Colt and 45 ACP and never had any real issues. No leading, clean handling, and easy on the wallet.
GeoDudeFlorida
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They make color-coding loads easier, too. Blue for Smurfs, Green for Zombies, Red for Dragons... 
Maybe. I didn't coat them, so I assume the maker did it properly. I think I just got a little overzealous and accidently pushed them too fast. I was aiming for about 1400 fps velocity.
AJC1
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Hay I resemble that remark.... I have colors assigned to mixes. Warm colors, oranges and reds bhn 9-10. Cool colors blues so far are bhn 12 and up.They make color-coding loads easier, too. Blue for Smurfs, Green for Zombies, Red for Dragons...
P Flados
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All of the folks claiming what cast bullets can not do without sharing any real basis really frustrates me.
I cast a lot of bullets. I would guess around 10k per year. I use range scrap for alloy.
I use tumble lube (BLL) for low power stuff (32 ACP, 38 Sp, 380, etc) and ASBB shake & bake powder coat for hotter loads. Depending on the situation, I generally use all available load data along with Quickload to figure out what likely maximum charges are. If it is a high pressure round, working up loads works fine. For rounds rated only for lower pressures, "pressure signs" are pretty worthless for assuring safe loads.
My use has included 9mm, magnum revolver stuff (327, 357, 44), IHMSA stuff (7 TCU, 30 Herrett, 30-30, 357 Max), and some AR-15 rifle loads (300 BO and 357 AR Max).
For pretty much every cartridge I have been able to find a full power load with good accuracy and zero leading. Best velocity has been just over 2100 fps. This was for a 357 AR Max rifle load that was probably right at 55000 psi. For some of my bottle neck stuff (30 Herrett and 300 BO with lighter bullets for example) I have had accuracy go away with no leading when pushed too hard.
As you go above around 2000 fps, you are getting into territory where cast bullet limitations may indeed limit usefulness in some guns. On the other hand I believe the right combination of bullet design and gun can get into the upper 2000s and still do fine (for example search on 30 XCB). This is true with either powder coat or traditional lube.
On the flip side, powder coat does not prevent leading. I too have found bad bullet fit situations to cause leading even with PC.
I cast a lot of bullets. I would guess around 10k per year. I use range scrap for alloy.
I use tumble lube (BLL) for low power stuff (32 ACP, 38 Sp, 380, etc) and ASBB shake & bake powder coat for hotter loads. Depending on the situation, I generally use all available load data along with Quickload to figure out what likely maximum charges are. If it is a high pressure round, working up loads works fine. For rounds rated only for lower pressures, "pressure signs" are pretty worthless for assuring safe loads.
My use has included 9mm, magnum revolver stuff (327, 357, 44), IHMSA stuff (7 TCU, 30 Herrett, 30-30, 357 Max), and some AR-15 rifle loads (300 BO and 357 AR Max).
For pretty much every cartridge I have been able to find a full power load with good accuracy and zero leading. Best velocity has been just over 2100 fps. This was for a 357 AR Max rifle load that was probably right at 55000 psi. For some of my bottle neck stuff (30 Herrett and 300 BO with lighter bullets for example) I have had accuracy go away with no leading when pushed too hard.
As you go above around 2000 fps, you are getting into territory where cast bullet limitations may indeed limit usefulness in some guns. On the other hand I believe the right combination of bullet design and gun can get into the upper 2000s and still do fine (for example search on 30 XCB). This is true with either powder coat or traditional lube.
On the flip side, powder coat does not prevent leading. I too have found bad bullet fit situations to cause leading even with PC.
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That will require some elaboration. I don’t have any problem believing 45 ACP and 38 Special or even 357 Magnum can push both jacketed and coated cast to similar velocities without leading. It’s a harder sell if you want to talk about 308 Winchester or 223.
Are gas checks required? Are bullets sized 0.001 or even 0.002 inches larger? Are very hard lead alloys required or are softer ones beneficial?
Riomouse911
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The only real differences I have seen between shooting lead/lube and coated lead bullets are:
The lack of lube smoke left in the air when shooting coated bullets, especially at indoor ranges.
And, the need for a bit more flare in the case mouth when loading coated bullets. This is so you are sure not to strip off any of the coating by catching it on the case mouth when seating. (Same goes for plated bullets.)
I load both to identical specs in revolver rounds from .32 to .45 and have yet to have a leading issue.
Other than these two things, I cant tell the difference on targets between the two.
Stay safe.
The lack of lube smoke left in the air when shooting coated bullets, especially at indoor ranges.
And, the need for a bit more flare in the case mouth when loading coated bullets. This is so you are sure not to strip off any of the coating by catching it on the case mouth when seating. (Same goes for plated bullets.)
I load both to identical specs in revolver rounds from .32 to .45 and have yet to have a leading issue.
Other than these two things, I cant tell the difference on targets between the two.
Stay safe.
P Flados
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DMW1116, by the wording of the OP, I would say that there is a good chance he was thinking handguns. It is common to find load data for both cast and jacketed in handguns. Cast bullet rifle load data is generally not available from "typical" reloading sources. Numerous responders seemed to have figured this out and also appear to be thinking handgun.
However, as you noted there is the possibility of using cast in rifles (or specialty handguns like some of mine) that allow for velocities above where cast bullets have any reasonable chance. However, this is probably irrelevant to what the OP and most responders had in mind.
However, as you noted there is the possibility of using cast in rifles (or specialty handguns like some of mine) that allow for velocities above where cast bullets have any reasonable chance. However, this is probably irrelevant to what the OP and most responders had in mind.
adcoch1
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Like all things in life, it depends. I voted like jacketed thinking that I'd run them at whatever reasonable velocity I'd run a jacketed bullet at, in the guns I shoot cast in. PC on a 200 grn cast bullet, properly sized in 35 whelen? Yes, I use them for cheap fireforming fodder at 2100fps or more. In a 38 special? Absolutely! In my 44 mag redhawk? Yes, it loves PC bullets at medium high velocity mag loadings. BUT!!! All of these bullets are appropriately sized to the bores of the respective firearms, and loaded with attention to flaring the cases to keep the PC in good shape. I haven't had leading with PC yet. I'm sure I will someday, but for now I love me a cast PC coated bullet in most of my guns.
I think the original question was most likely limited to handguns. There are enough replies referencing rifle cartridges that without more context its difficult to tell what is meant later on. Can one push a 200 grain coated cast bullet from a 308 Winchester at about 2200 fps without a problem? Most likely. Can it also be done with a 135 grain coated cast bullet at 2800 fps? Probably, but I’d say it requires some special preparation and knowledge.
AJC1
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I bet if one wanted to find the limit a cast Lee 55 grain in 223 would give you enough velocity for failure if one was looking.
.45Coltguy
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True enough. If shooters want velocity and reliabilty, they'll stick to jacketed, not cast. Not at higher fps levels.
I have enough 135 grain coated bullets that I can do a little experimenting with my 30-30. H335 didn’t cause leading at 16 grains. I want to go up and try to tighten the groups anyway. Might as well see what happens. I was going to stop at 18 grains but maybe I can go higher.
EricBu
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Use cast data, but you can push them harder. Keep in mind, the coating doesn't change the hardness, it just makes them shed less lead. So if you want to push them up to jacketed velocities, you'll still want a BHN of 16 to 18, regardless of coating. And if you want mouse farts at super low velocities, then you should probably go with a BHN of 12 so that the bullets will obturate correctly. A BHN of ~ 15 is a good all around hardness for a Hi-Tek coated cast bullet, no leading and good accuracy up to 1400 fps in 44 Mag for example, but still performs well at 700 fps out of a 44 SPL. The point being, just because it's coated doesn't mean you can ignore the BHN. A BHN 18 coated bullet at 450 fps will still not obturate, and will likely gas cut - leading even with the coating. The coating basically replaces lube, it does not impart any magical properties to the lead.
Get the lead bullet spinning fast enough and they'll tear themselves apart. I believe the limits for good accuracy are around 120,000 to 140,000 RPMs and disintegration will happen around 200,000 RPM. It varies depending on the exact alloys used, Jacketed bullets will have the same thing happen if you push them fast enough - Think light bullets in something like 300 Weatherby Magnum.
That would be entertaining, once. It's not hard to get above that limit with a fast-twist 223 barrel.
AJC1
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I want to cast a 223 heavy ish bullet to shoot out of my 223. Noe has heavier molds but data gets real sparse. A 70ish at about 2k fps would be nice.
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Barbaroja
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I was referring to handguns as I believe that was the OPs question. There are of course limits to anything, but lead Bullets are capable of a lot more than most think and that the majority of us are not skilled enough casters and reloader to have figured it out.
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