404 Jeffrey - Oh Boy, another project!

I use .461" sized, hardcast bullets in my .458" to .459"-grooved barrels all the time.
Prefer it.
No leading or unusual behavior at all.
Chrono results are similar to what I get with .458"-diameter jacketed and monometal copper and brass,
with same charges.

You are measuring "groove diameter" as .415".
"Bore diameter" is hard to measure unless you have an expensive set of gauge pins graduated in 0.0005" to 0.001" intervals
I would happily use .418" diameter lead bullets in that barrel.
Use .416" diameter jacketed and monometal copper and brass also.

Powder-Coat Paint is recommended on the cast lead bullets. Sizing after PC-Paint works great.
The PC-Paint is like a lube on the bullet, no other lube necessary.
 

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