Range trip today after a complete cleaning of the breechplug with solvent and a drill bit. The blowback was much less then before. Not as good as the brand new plug, but workable. I still need to get another new plug to compare.
I also switched to new MMP sabotsfrom the factory Shock wave sabots. Much better accuracy with no other changes. Both the HPH12 and 24's shot about the same and not much difference in loading difficulty.
I am now getting a consistant flyer that is 1-2 inches high from the rest of the group. Two shots touching and then the flyer. I had three different 3 shot group and all had the same problem. This was with weighed charges of 777, 250 and 200 Shockwave and it wasn't the same shot number in the group. No variations in loading, swabbing, or bag placement.
Any thoughts on what might be causing this?

Also, I had to shim the Weaver base to get enough elevation. Do you think switching to a Warne steel base would help with this?

It's hard to say what your flyer is caused by. As you said, you're keeping everything the same, so some of the things Iwould suspect; that the bullet was not seated with the same pressure as the others, the bullet was somehow different then the others, either deformed on the way down the barrel or from the factory, or for some reason one of the sabots held on to the projectile longer then normal. Then there is of course you. As hard as I try to be consistant with how I address the rifle, I constantly catch myself being just a little different from time to time.

I guess that is the appeal of the muzzleloaders to me. Unlike a centerfire where you can put numerous shots in the same area on a target time and time again, no matter how hard I practice to make myself a perfect shot with a muzzleloader, something comes along and reminds me I am not perferct. []

All you can do is keep trying and see if you can figure out the flyer. Some projectiles are more prone to flyers then others.... Good luck

I havn't ruled out the idiot behind the gun factor, but all the flyers today where high and in almost the same spot on the target. I seem to attract strange problems that nobody else enounters. Not just with guns either.
Off to Cabelas in the morning. I'm going to pick up the steel base, some more bullets and a breech plug. I want to try the Barnes spitfires and see how they shoot. This working up a load is expensive.
I have a bunch of 45 Long Colt bullets. I'm going to use those and the surplus T/C sabots for practice.

Well I was shooting my Knight Disc today and having the same luck. I would shoot five shot groups. Three or four would be right in the bull or in a real tight group, and then I would throw one. I was blaming myself. Twice when I got a flyer I knew it was me. One though really threw me for a loop. That with with a Shockwave. After I shot I kept checking the bull becuse I was certain I had not mess up. I found the hit about six inches high at 12:00 o'clock.

Your also right about the cost of shooting. When I used to shoot only roundball that I casted, it seemed like shooting was next to nothing. Now I get all these different sabots, conicals, projectiles, rifles, and manI got figuring it up one night and about fainted...

Hope all works out for you and your rifle..

Cayugad, Heck a movie is around 10 bucks, a meduim drink is 6 and popcorn....... heck it's still cheaper to shoot. Ok well that's at least how I fib to myself.

an expensive trip to Cabelas. I picked up some APP in FFF, a Maxima steel base, Simms recoil pad, and some Barnes 245 spitfires. 19.99 for 25, I don't think thats too bad a price considering. Got some BC Sheath to try also.
In the morning I will try some weighed charges of Pyrodex, AAP and 777 to compare velocity. I should get a good idea of the powder/speed with any bullet so I will shoot some cheap ones for this test. I'm hoping my gun just dons't like 777 and that's where my problems have come from.