Your bullet should be of a large enough dia. to seal the bore upon obturation.
I am having trouble trying to determine how you measure the powder charge when you say "weight is what ever fills the case i don't weigh the charge ...."
Do you just scoop the case into the powder, use a muzzleloader measure or what?
Most successful BPCR shooters either weight the individual charge then slowly trickle the powder into case via drop tube, or use some sort of measure to meter the charge, then use the drop tube method.