I am curious, not because of the caliber, but because of other parameters you are using similar to mine.
One, you're using smokeless powder and probably pushing velocities similar to my .35 Whelen. Two, you're casting with wheel-weight alloy, which is what I'm using. Three you're mold is .503 diameter - is that bore diameter? groove diameter?
When you're using smokeless powder, let me know if you have better luck with full charges of slow powders or reduced charges of fast powders.
What is your after-patching diameter? How does that compare to bore and groove diameters?
And finally, how fast can you run air cooled wheel-weight alloy?