Funshooter, you mention your bullets are "close to pure lead". What is your alloy mix?
I ask for three reasons:
1) pretty much all alloys are "close" in composition, but the resultant can have wildly varying properties. A little bit of wheelweight or linotype skews affairs quickly.
2) You didn't quench. Lordy, I hope not. The .45-90 is not the place for hard bullets at all. Your alloy of choice should start around 30:1 Lead/Tin
3) Different alloys will shrink at specific ratios of dimension after cast. Pure lead shrinks the most, heavily alloyed (lino/WW) the least. If you have a bullet mould meant for soft lead and cast with alloy, the bullets will be oversized from the start.
If you haven't visited this site, do so, read and learn:
http://www.lasc.us/CastBulletNotes.htm