Wasted another entire day trying to make this thing shoot.
First I tried some of the 225-grain gas checked bullets from the excellent iron mould Tom sent me to try. At 4.5 cents a pop, I'm simply not going to buy Hornady checks to shoot in .45 ACP. I'll buy factory ammo long before I do that. So I tried Josh's aluminum checks which didn't want to stay on the bullets. Damn near ruined my suppressor with them, should have known better than to try running them through it. I got true keyholes at 25 yards and the checks ended up shredding in the blast chamber and second chamber of my can. No other damage other than some faint baffle strikes near the muzzle end of the can. I only fired three of those before I quit, and only one hit the backer at 25 yards.
So back to the powder-coated Lee 230TC. I also tried these in my M&P .45 and they shot very well once I seated them deep enough for this absolutely throatless wonder of Smith & Wesson Lack of Engineering to chamber them....even sized .451". This thing barely chambers factory ball ammo. Since I was getting good groups with the M&P with the bullets seated deeper, (1.200" vs. 1.208") I broke out the AR-45 again. Still getting 2.5" round clusters at 25 yards. This is all with Hodgdon Universal powder because anything faster won't cycle the AR-45 and Unique blows my eardrums out via ejection port noise due to it's weird, long burn curve. So I tried the AM 45 230L, powder coated, sized .4525, .452", and .4515" with different crimps each. No dice, no change in groups. Loaded some more Rainer round noses with the same powder charge, shot a 1" hole with ten, so THAT isn't the problem. Went back and loaded some AM 230C bullets with regular lube and tried them at .4525" and .4515. Worse than ever, 3-4" ten-shot groups at 25 yards. I can hit better than that by throwing a rock.
Size doesn't matter. Front shoulder doesn't matter. Nose profile doesn't matter. Crimp doesn't matter (except for function). Case brand doesn't matter (all same headstamp). Flat base or bevel base doesn't matter. Powder coated or plain lubed doesn't matter. The only thing that matters is whether there is a copper jacked on the bullet, no matter if just thin plating or a heavy, ball-style stamped jacket. I'm simply at a complete loss as to why this thing won't group with any kind of cast bullets.
Maybe I should have gotten some copper-colored powder coat and seen if I could fool this carbine into shooting some decent groups.