Or will the stock .577 caliber (.584) bump up if cast in a softer mix?
I don't thing so. Your lead cast bullet has to be .598 in diameter minus thickness of 4 layers of cotton paper, which I'd strongly recomend you to use with BP. When you get the real diameter of bullet depending of paper thickness, some people prefer to use just a bit larger bullets in diameter any way and they say it's improve shooting. The lead bullet hardness could be 5 (pure lead) or for .577 DR I'd personally prefer hardness 15 (wheel weights lead, clip on + 2% of tin, hardened in water).
If you 100% sure your .577 DR has .598-.580 grooves and bores, you could ask machinist to increase internal diameter of mold to needed size.
I made for myself several bullet sizing dies to get different bullet diameters for using with paper patch or without and I have to say it's very helpfull.