Trying a new source of powder:
This seems to be working much better. I must admit I'm standing on the shoulders of giants here. If it weren't for all the info posted on this forum then I wouldn't have even thought about trying any of this. Thank you to all that have posted pics and tested their results.
You mix the powder with the lacquer thinner in about a 1:4 powder to thinner and shake shake shake until the thinner is dry and the bullets are coated:
Initially you may think you don't have enough powder but just keep shaking until everything dries. Once dry bake in the oven at 400 for 10 minutes just like the label says.
That's the first coating and I plan on doing a second one tonight. These will be loaded for shooting tomorrow. The previous HF batch will also be tested.
TBC...
EDIT:
I failed to mention something that I find to be a HUGE WIN for powder coat so far.
Since you have to shake the bullets in the bucket until the thinner evaporates off that means the bullets are dry. For whatever chemical reasoning the baking and cooling of the finish does next to nothing to make the bullets stick to each other. I just did a rather large batch just to prove this to myself. The Powder by the Pound powder is polyester based while the HP powder is epoxy based. Go figure the HF bullets stuck together a little more but still not as bad as the two part paint tumbled bullets. The HF powder may only be $5 a pound but the PBTP is so far around $10 to $20 and seems to be coating much better and isn't sticking really at all. I'm calling PBTP for the early win as long as it performs and .40SW should push this for a good pressure test for leading.
Oh, and yes I saw some of the bullets are fragged. I plan on culling as I drop them in cases during loading tonight. I didn't want to look at each of them right now while I'm trying to cook everything and coat a second time. I see no need to handle twice when I have to handle them during loading anyways.