It just doesn't matter
At least not for now. Today I took the Lyman flinter back out to try Lemoyne's suggestion of using .535" balls.
Here's how it went today. Each load was shot at 50 yds using 100 gr of Goex FFFg, spit patch between shots and a thorough cleaning of the bore with T/C #17 between each group.
Group 1: Base line .530" ball/.020" Oxyoke prelubed patch
Group 2: .535" ball/.015" Oxyoke prelubed patch
Group 3: .535" ball/.018" Pillow tick liquid wrench lube
Group 4: .535" ball/.015" Oxyoke/ 100 gr Goex FFg
Results: Groups 1, 2, and 3 all came in at 1.5" for 3 shots (+/- a couple thousands). Group 4 with the FFg measured 1.9".
The .535"/.018" combo was a real bear to start down the bore. (Wish I would have had Semi's mallet). I did note that the FFg had more of an ignition delay than the FFFg.
Now I don't know if it make a difference or not but the .535" balls did have a larger spue cut tit than the .530"s that I had cast. I did make an effort to be sure this was pointed straight up when I started the ball.
So I guess for now I am just going to have to shoot the crap out of that barrel and get a couple hundred shots through it before I get serious. But even now, its definately a 75 yd deer buster for sure.