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.430 cast bullets may not be the best, measure the cylinder throats and do not use a bullet smaller then the throat measurement, smaller then throat bullets can enter the barrel throat a little sideways and that raises heck with accuracy (more so with softer bullets). Rule of thumb is .001/.002...
You are right, its not cut and dry, Crimp, throat size, bullet size,Powder, primers, all play a part........I once read a test were rubber bullets was used and only primers No powder and the spread was + - 200 fps.
Go over to www.Marlinowners.com and ask this question, you will be surprized at the answers. In Ranch Dogs postal match groups from 444's and 45-70's were running .75 and smaller and most times thats with Hardcast bullets. If you know how to get a marlin too shoot they will do their part.
You would be hard pressed to do better then the 25-06, its a great cartridge for up to Muledeer size critters, very flat shooting and works well with many powders, brass is very easy to get or make from the other family members of the 06 clan and it darn near comes in about every config of...
First off you should see higher velocities with hardcast bullets vs jacketed and the same charge of powder, why Hardcast bullets are by nature Slicker (lubricity) then add a little lube it helps as well. Hardcast can seal better if the powder charge/bullet hardness can obturate the bullet...
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