I gotta be honest but .575 for me is probably the best I'll ever do.
The load Im currently trying to work up is 54grs of Goex 3f, with RWS caps and a 460gr .575 Minie.
Bullet lube is probably where Im gonna get in trouble. When I initially cast and sized this current batch of Minies, I used Lee Liquid Allox that was on hand and that worked for a while, but that was applied 2yrs ago and that stuff has hardened.
I was looking into this stuff but I feel going with the original period recipe would be the best course now.
2500+ 1x4” Hollow sticks in Bags. Working temp: 60F, melt temp 165F 2500+ is a great all purpose lube that has been used in a wide range of pistol and rifle cartridges with great results. I have used it in the 38 special, 45Colt, 454 and 470NE. This
lsstuff.com
I guess the first question is why is .575 the best sized bullet you'll get?
Do you have a mold and casting your own or are you buying yours or getting them from a friend
Do you have a sizer or are you shooting them as cast? Sizers are pretty inexpensive, especially when compared to the price of a mold.
Ideally, your mold would cast a bullet maybe 1 or 2 thousand oversized of your bore and you would use a sizer of the appropriate diameter to swag down you bullet to a thousand or two below your bore size.
However, in your current situation, where you say .575 is the diameter of your bullet, but the bore size is .579, then you could get a sizer thats .577, put the bullet in the sizer and "bump it up" to .577. It's not ideal, but it may be better than shooting a bullet that's 4 thousand undersized.
Lube's-
With black powder, you never want to use a man-made product for a lubricant. It needs to be of a natural occurring substance. That Alox your using is for hard cast bullets being shot at higher velocities than what you're doing. That black powder fouling in your barrel is not a bad thing as long as it remains soft where it actually provides a lubricant for your bullet to prevent leading and helps in the ease of loading. Where it causes a problem is when it gets dried out, it gets hard. So to avoid this, you either swab out the bore after every shot, or you use a lube that keeps the fouling soft. Most lube recipes for what you're doing uses bee's wax as its major ingredient, coupled with some type of fat to soften the bee's wax. Lard, tallow, Crisco, (the white creamy stuff), even olive oil can be used for the fat portion of the mixture. Years ago, when I shot in NSSA, my lube was a mix of bee's wax and Crisco. The ratio of the two products varied with the changing with the season. Less Chrisco in the summer as the lube would get runny. I shoot a 45-70 Sharps black powder cartridge rifle now and my lube of choice is SPG lube. It's major ingredients are bee's wax, lanolin and tallow; notice, no man-made products, (but sheep-made is fine). If you can't find bee's wax, you might use ordinary candle wax as the main ingredient along with a fat. There are all kinds of recipes for your bullet lube available with a little web search but stay away from anything that's for center fire. In fact, some of the things you know about center-fired bullets do not apply to muzzleloaders, black powder cartridge rifles, and .22 rimfires, but that's a topic for another time.