Thanks for all of the great input, guys. Bullet hardness is most likely the culprit here and it sounds like I really need to fire up the melting pot and just DO it.
Along with a lot of lead and other necessary (and maybe unnecessary) casting equipment, over the last couple of years I have accumulated 20 to 30 molds including some good ones in 41. Lyman 410459, Lyman 41032, RCBS 41-210-SWC,
RCBS 41-210-KT and an NEI #411-190 (200gr? full wadcutter). Yes, I tend to overkill but prefer to have options. Powder coating has indeed interested me but is one of those things that I've sort of put off learning until I get the hang of the casting process itself.