Sharp...What type of problems are you having with your patches??? Are they burning through??? Or is the rifling cutting them??? Can you post a pic of a fired patch....

In my .54 flinter with a Rayle barrel...I shoot .530 cast balls...with a .015 patch lubed with SnoSeal...I can start the ball with my finger and it shoots 2-3 inch groups at 100 yards with 80grs FF...If I go to a .020 patch...the rifling cuts the patch and the groups open up....If I go to 100-120 grs FF then the patches start to burn through...I remedy this with some hornets nesting between the powder and ball....