Handgunr,
>Many cylinder measurements can be .002-.003 over bore. and sometimes greater. If a cast round was sized to the bore, in the majority of guns, it would be hopelessly sloppy when exiting the chamber, and easily misaligned when connecting with the forcing cone. <
I understand the problem, and understand that there are many fixes out there. My most accurate loads for .38 Special use the Remington factory lead 148 gr HBWC, and I shoot them in an 8" Python. Those bullets run .360+" any day of the week and the groove diameter for this gun is 0.355." I have a couple of Smiths that like the same sort of load, but with the Hornady 148 grain HBWC and it is, nominally 0.357."
Some revolvers do, indeed, run very large in the cylinder throat. Colt SAAs come to mind and some of the Smith .45 Colts and .44s, too. However, Ruger .45 Colts have been, very often, undersized to as little as 0.449" for cylinder throats and sport a. 0.451+ groove diameter. There is no fix, really for a grossly over-sized cylinder throat, but at least I can ream an undersized one to a favored diameter. Still, even if the throat is over-sized, the barrel forcing cone can be set to about mid-way on the gage and will then handle the over-sized bullets needed for the over-sized throats.
Unsized cast bullets will generally shoot very well and one should not size them unless they need truing, and then just enuff to true them, or unless the loaded ammo with the larger bullet will not chamber.
Undersized lead bullets, smaller than the throats, generally mean leading trouble, but not invariably so. If one shoots a really hot load and the bullet hardness allows them to bump up to throat diameter, sometimes they will work just fine, sometimes not.
50-70 years ago, Phil Sharpe did experiments with over-sized bullets. The bullets were over-sized in steps to the point where the bases would acquire fins from the metal displaced from sizing and engraving in the bore. His conclusions were that fins are detrimental to accuracy, generally, so dramatically over-sized bullets simply can't be that good.
I'll very much agree that there is more latitude with cast bullet size than with jacketed, but my interior ballistics program, QuickLoad, allows for over-sized jacketed bullets and does not complain until it gets to a certain point. Richard Lee, in his loading manual, states that over-sized copper jacketed bullets, even those that are markedly over-sized, will only raise pressures by what seems to be a modest amount compared to the total of a high pressure load. The QL program gives more credence to core hardness, jacket hardness/temper, and bearing length than to bullet diameter, and that follows what the NRA found out many years ago.