Another subtlety I just noticed...
Thanks Gary for your comment, I will be incorporating the opening/taping method you describe...although I hate to use the whacker at all and am trying to get around it all together...?
Here's another little subtlety I hadn't noticed...this is the best picture I can get to show this anomaly. I've taken about 30 shots and deleted all but this one as it shows a dimple...an area about .001" deep, almost like a drill center, I'm guessing where the center of the nose is lower than the outer edge. I think this helps to lock these casts into the mold.
Imagine the mould open and that little bump in the mold forcing the cast to get over it...all the same time those square lube slots are keeping it from having any slack to rise above this bump on the nose of the mould...
I can put a straight edge over the nose of the cast and see daylight under the straight edge in the center of the nose...that has to help to lock this cast into the mould.
Attachment 188278
I think I need to devise a method to remove this bump evenly while the mould halves are closed together...? But how? I have a Dremel and lots of little polishing tips.
Maybe a small white fiber barrel shape tip with some lapping compound on the bottom...?