OK
Ill try to answer all the questions
No questions are simple
Im using 2F black powder
have used 100 grain, 110 grains and 120 grains and various bullet weight. The best so far was the 110 grains of 2f with a lighter projectile. I just forget the exact weight. The worst was 120 grains of BP
The standard loads for a 450 x 3 1/4' BPE was 110 grains of BP with a projectile weight of between 270 to 350 grains.
The right barrel although the biggest shoots to best
I have not thought about swagging the 475 bullets down,
Where is Corbin? Im not rich but if I have to spend the money then that's what have to do.
I have not slugged the bore all the way to the muzzle. Ill do that
Ill have to check to see if a 470m cal bullet will chamber
OK I need to get Wrights book and read that re swagging with a hammer
Not quite sure how hard the bullets but I can cast then soft and Ill try to stick with lead bullets
If/when I get my dies made Ill make sure they have grease grooves. (Im not going to die in a ditch about not paper patching but Ill avoid it if at all possible

:):)
Thanks so far for all your input, Ive got lots to think about