Powder coating looks like it might have potential. My search skills aren't the best, so maybe one of you can direct me to threads or posts that speak to someone's getting the equivalent of paper patch performance from powder coating. The parameter measure standards for .30 cal for paper patched are 2500fps or better with consistent (10 rounds, 100 yds) 1.5 MOA or better accuracy. If someone is doing this with powder coat, ideally in .308 or .30-06, I haven't been able to find it. I'd be wiling to look beyond paper patching if that's there. Until then, I'm still moving toward a 2700/1MOA goal in PP .308 - something a bunch of us know to be in striking distance.
The lure of the ease of powder coat is powerfully seductive, if only it just worked...