On the same quest!
Ian,
Though an ocean separate us, we seem to be on the same quest!
I recently purchased a Ruger M77/44 in hopes of producing decent rifle accuracy with cast bullets as well. The Elmer Keith bullet to be exact. I cast and cast like crazy to be honest! I would almost rather do that than anything else concerning firearms, almost.
My Marlin 1894 rifles have had fair accuracy, 2" groups at 50 yards is about the best I can do with lead plain based bullets. I wanted better and never got there. I didn't use gas checks and have heard that I could have improved accuracy had I used them. Maybe with the Ruger, I will have to go that route too, hope not.
I must say that my loads for the Marlin rifles were clocking out of the 20" barrel at 1800fps and most claim that lead bullet accuracy diminishes greatly at anything over 1600fps.
Back to the Ruger: I have been working so much that I haven't had time to get to the range as I would have liked to but I have run several loads through it. One showed great possibilities. It is with HS-6 powder. I had to call Hodgdon for it though as there was no data anywhere for the combination I had chosen. (I had some made up with the weight of powder that the technician suggested even before I called though, took an educated guess!

)
The load he suggested was 14.0gr of HS-6 under that Elmer bullet. I have only shot it inside at ranges under 25yards but, from a rest, I have gotten one hole groups with it, Like a leaf of clover.
The reason I bought the Ruger is because of the faster twist of the barrel, 1:20". The Marlin and other rifles have a 1:38". The faster twist SHOULD lend itself better to heavier bullets, 280gr and up. The only problem with them is that you may have problems getting them into the magazine. My Elmer's don't fit either but, I want accuracy above all. As cast, they are running in the 260gr area too, so maybe.
Hopefully, the weather will break and I can get outside, right now there is snow, snow and rain! Even though mine is the stainless version, I have no desire to shoot for an extended period of time in inclement weather! Spoiled I guess!
We will have to keep in contact as we work through this together a world apart! Ever think about immigrating? I wouldn't live in a state that didn't allow me the right to have a handgun, let alone a country!
p.s. Welcome to the forum too!