Back from the range (sorry for the delay) and am happy to report success. Breech plug fowling was certainly the No.1 problem, swabbing probably contributed to the problem. With these problems corrected, I didn't change anything else. I never had a mis-fire and only went 7 shots between cleaning the BP with drill/fingers. Found it plenty crusty even with that. Thankyou all for the help. Now I can get on with working up a load for the Wife's Elk.

No worries Ron with me using a drill. Retired Engineer and hobby machinists, I was very careful and understand the issues. Embarassing that I didn't figure out the carbon. I soaked it and bought all the stuff and thought it would soften it. Got it now.

Maybe I should use a new thread for loads but have this from todays shooting.

Used Win.209 Shotgun primers only.

Shot Federal FPB 350 gr., 100 gr.BH209. 3-1/2" group but this load really belts you.
Then I shot 270 gr.Bore Lock, 100 gr.BH209. 4-1/2" group. Much more comfortable to shoot.

Shot both bullets with 100 gr. Pyrodex. Swabbed between groups but not between shots. Bore lock bullets scrape the barrel down so were fine and the FPB bullets seemed reasonable to seat to the powder for three in a row anyway. Groups worse than with the 209.

Muley Hunter, curious why you don't like the bore lock bullet for elk? And anybody, Do you think the bore lock bullet holds firm enough in the barrel to hold the BH209 powder snugly in position or do you think it would loosen during the day hiking and on horse. Seemed reasonable pressure seating while loading.