I have to wonder just how important the crimp is on these checks, as the bullet is being pushed down the barrel by the high pressure of the charge. If the gas check were to fall off when it hit the rifling, that would mean that it has already exited the cartidge. At that point, wouldn't the gasses already be pushing it down the barrel?
I am looking at it like an overcard that is used under the bullet/ round ball and over the powder in muzzleloading. I use 1/8" felt, and I have yet to have one not exit the barrel. I also use a felt wad over the powder in a BP revolver and there is agap between teh forcing cone and the cylinder and they also all exit the barrel. I would guess that a certain amount of the gas checked bullets I shoot have the gas check fall off after exiting the barrel already, and I can not notice any accuracy problems.
I'm thinking that if the outside diameter of the AL check is sufficient to create a seal to stop the gas cutting, it will in essence become a plunger that will be forced down the barrel.
Maybe I'm all wet here, but a lot of the fun of this hobby is making things work, and rolling with the flow when they don't. That's why I frequent forums like this to get the info from other peoples successes, or failures, and try to use them. If I wanted everything to work like clockwork, I'd probably be shooting jacketed bullets where the variables are pretty much set. Man! Just thinking about going back to jacketed bullets almost leaves a foul taste in my mouth!