Bigdog - how deep is the rifling? That ball is already .017" smaller than the bore.
In the pics, the rifling looked to be at least .020" deep. Your way undersized ball needs to be patched to reach the bottom of the grooves or the bore will foul badly.
With the ball 8 1/2 thou.(with .020" deep rifling) undersized per side, and .020" rifling per side, you'd need a .0285" patch just to reach the bottom of the grooves. That's heavier than 12 pound denim which is .025" or thereabouts.
We normally use a ball .005" under bore size with a .020" denim patch. With WW (HARD) balls, .010" to .015" undersize and the same or slightly heavier patch usually works with low pressure loads.
Smoothing the angles to a radius at the muzzle's crown might be necessaary to assist loading.
Are you shooting hard or pure lead?
-------------------- Daryl
"a gun without hammers is like a Spaniel without ears" King George V
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