In my .40 caliber flintlock, I shoot a .390 home cast ball with .018 WalMart pillow ticking and homemade lube which consists of 2 parts bees wax, 8 parts castor oil and 1 part Murphys Oil soap...I shoot 25 grs of Goex FFF for small game and have shot up to 60gr for longer ranges...

In my .54 flintlock, I shoot a .530 home cast ball, same ticking and lube and 80grs of Goex FFF for deer hunting...I have gone down as far as 50grs FFF for small game and target shooting and used to use up to 100-120grs for hunting (my barrel is 1 1/16 thick at the breech)...Without knowing how stout your barrel is I wouldn't suggest going over 90-100grs of Goex FFF or Pyrodex R-S...

When I used to shoot a .45 flinter, my small game load was a .440 ball and 40grs FFF and my deer load was 75grs FFF....

Point being...Start with a ball .010 smaller than caliber and 40-60 grains for targets for small game and 75-100 grs for deer....

I used SnoSeal for lube for 30 years or so, it works well....

I prefer to buy cotton ticking from WalMart and lube and cut my own patches because it's cheaper and I had patch burnout with the pre lubed patches....

Start with a lighter load and work up...Always look at the patches after shooting, this will let you know if you need a bigger ball, thicker patch or some type of wad, nesting or buffer patch between powder and ball....

As Cay mentioned, my cast balls have a sprue, I just center it when loading and put it up...