I have had my best results with soft bullets, cast from 20 to 1 lead/tin or 50/50 wheel weight/pure lead. Bullets need to be able to expand on firing. That gets rid of the heal and allows the slug to expand and fill the grooves. Every original rifle I have slugged has grooves that taper .003" to .005" in depth. If you drive a slug through and measure .535" groove diameter, it will actually be .538"-.540" at the chamber mouth. I've seen as much as .543" just ahead of the chamber. Most moulds are ~.535", which is too small.
The Rapine bullets are fine in carbines, but don't hold enough lube for black powder in rifles, especially if your bore is less than perfect. You need a grease wad between the powder and bullet. An alternative is to buy the Owziak bullet mould. It has much larger grease grooves and a beveled base, sort of like the Wilkinson design. When the heel collapses, the base doesn't become dished, which helps accuracy. Jim Leinieke and I designed it for N-SSA shooting (50-100 yard). It weighs ~375 grains. Jim and I have both won medals with this bullet. If anyone is interested, I'll post ordering info. I'm on the road and it's at the house.
When you cut off 50-70 cases, size them and neck ream to .512". The thinner walls help case expansion and feeding. You can still crimp the thin walls with CH-4D 56-50 dies.
Use a powder compression die! Pre-compress the powder so that the bullet just seats against the charge. This will usually fix the problem of bullets sticking in the chamber and generally makes loading a lot easier, with no deformed noses or cocked seating. I made my neck sizer into a compression die by squaring up the end and recutting a smaller end radius. This works fine with card wads and still allows it to be used as a neck sizer.
Using the Owziak bullet, I load 32 grains of Swiss FF with a pasteboard card wad. Lube is 50-50 bees wax/olive oil. This will chrono at about 850 fps and is very clean and accurate. At an N-SSA 50 yard match, I shot 8 rounds, got 6 hits, relaoded (from a Blakeslee box) and was aiming at the last hanging clay pigeon when a teammate hit it. Total time, <45 seconds.