DEAN 2: Very similar load to what i use with the 350 Hornady (RN). It was the bullet I settled on when I started with my first 45.70. I'm at 47 gr of Re 7 with Rem brass. Right around 1800 fps and as you say it doesn't beat you up although off the bench you do know you've shot something
I've never bothered with cast bullets. Hornady's are affordable enough that you can buy as many as you are ever going to want to shoot. Why compromise the ability of a fine cartridge with an econo bullet unless you are going for some historical or traditional effect.
For bear defense...my choice would also be a 350 Hornady (RN)....and if you ever see our spring bear camp or our fall camps, you will see a 45-70 somewhere within reach.
I