Thanks for the info.I appreciatthe responses. Here is what I have done:

I use triple 7 (fresh). Swab every 2nd round, use a peep site (exact same model I use on my Thunderhawk).Crown is fine, no dings and uniform, no ram rod wear, rifling is clear and not pittedand I have put roughly 175 to 200 rounds through this rifle. As for a load, the reason I bought the rifle is because TC advertised it would accurately use larger powder charges with a high pressure sabot. It is the BD model. I started my loads at 60 grains of powder and worked my way up. It was reasonably accurate with 360 grain sabots at 70 to 80 grains of powder(not as good as my Thunderhawk though). I attempt 100 grains and it is all over the page not tight grouping, no repeatability. I am shooting sabots because of the rifling and because (at least on my Thunderhawk) I can get a little flatter shooting bullet with more muzzle velocity. I use a musket cap for a primer. Since I am going after Elk I cannot really use a load at 250 grains. Washington has minimums and I am thinking that may be to low. I do use a lighter load (in my Thunderhawk) for deer. 280 grains sabot in 44 cal. But for Elk I use 360 grain Keith nose in 44 cal sabot from Precision in Canada. These sabots are not off the shelf sabots. Precision puts out an outstanding product of which several professional shooters have used to win many competitions.

I hunt in Washington state so no projectiles can have anything but pure lead in them and no scopes. As Cayagap suggests I'll try a buffalo bullet just to see what happens, 375 grains sounds good. I have not tried pellets but will give them a trytoo. Thinking also I may try to find a gun smith who can work on muzzle loaders. Have him inspect the crown as sabotloader suggests.My eye may not be detecting any problem when there may be. I'll recheck the sites as Lemoyne indicates too. Just to make sure I'll take it off re install and go from there.Some people think a pie plate pattern at 100 yards is OK. I don't. I want a much tighter repeatable pattern. If I wasn't already getting those kinds of results from my Thunderhawk I probably wouldn't be that concerned. I expect the Black Diamond to at least give me results as good as my 12 year Thundhawk and bought the black diamond to allow me explore heavier loads in bullets and larger powder charges to assure penetration and knock down power on elk. I am planning a moose hunt to Canada and the guide indicates we can use muzzle loaders so I would like to use the Black Diamond on the hunt next year if at all possible.

I appreciate your feed back and will let you know how things go. You have given me lots of great idea's. Perhaps it is just a lot of little things, but my patience is wearing thin (two years of work).I'll start getting serious about shooting here in about two weeks in preperation for October hunts.

Steve