One thing to never forget about PC is that while it does add a mild jacket effect, it in no way replaces the need to match the alloy to the job at hand nor does it make up for poor casting quality. You still need to have all those fitment and alloy/powder-matching ducks in a row for it to work.
Speaking of fitment, here's a postulation of mine which has proven true in my tests so far at lower velocity: Size the body of your powder coated bullet a little smaller than you typically would a cast bullet. I'm finding that half a thousandth over groove diameter is quite sufficient for excellent accuracy and zero leading. I'd still recommend sizing a bit larger than that if the throat will accept it easily, but we want to avoid scraping off the jacket on the edge of the throat entrance, and the hard PC coating lets the bullets bounce around and self-center in the throat funnel a little better than bare cast bullets will. We'll see if that's true as the pressure is increased. Bullet fitment to the throat is still important, but that has more to do with nose size and SHAPE than it does with the diameter of the driving bands. I've just scratched the surface of PC with my subsonic rifle and pistol experiments, but what areas I have explored I've explored pretty thoroughly before deciding the system has merit enough to continue experimentation.