OldBuckstalker1187
I really wonder myself what is going on. In all of my TC 50 cal barrels I use a .490 ball and a .015 patch - I certainly could use the 18 but the only time I shoot PRB's are for play and Rondies.
If the gun smith slugged your bore and found it correct - i am wondering if you might have got some .495 dropped in the wrong box.... Did you take any of the balls to the gun smith?
Another question... have you rolled a just a ball down the barrel?
Do you have a mic... have you measured the diameter of the balls?
Just some thoughts off the top of my head....