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He mentions both Canada and the RSA in the OP.

Check the Canadian definition of a firearm. I'm pretty sure muzzle loaders are within the definition but they don't need a permit. The best thing to do is to call Canada Customs and ask. You don't need any unpleasant surprises to ruin your trip.

Ask around for people who reload shotgun shells. There's a bunch of them around these parts. They'd probably be glad to sell or give you small amounts. Ditto on the yard and estate sales. Just make sure the bag is tied shut! (I know about this!) I've also picked up a lot of lead in the form of...

The best thing for the OP to do is to find a piece of wood that is as close a match to the rest of the stock as possible and glue it in with a good epoxy. He can then re-inlet the barrel. It will show but at least it will look like an honest repair. Just filling a 1/4" gap with epoxy will always...

Anyone whose ever run a checkering tool across a stock knows that any claims to being a "deep penetrating" finish are balderdash. The only areas the stain or finish will really penetrate are the places with end grain. A powerful vacuum then pressure tank system works well but is expensive and...

.440's, .018 patch, and a coned muzzle. Easy to load and accurate to shoot.

I use bright red Rit dye on some of my cotton drill patches when I'm working up loads for a new rifle. They are easy to spot. I dyed a half a yard or so of the material just for this purpose.

It looks like a shooter to me. If you have any doubts, load it up with a hefty charge, tie it down to an old tire and pull the trigger with a long string while you hide behind a convenient tree. And please, quit using capitols, IT SOUNDS LIKE YOU'RE YELLING!

https://www.shotgunworld.com/threads/results-of-gun-care-product-evaluation.398836/

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Sometimes the solution is a smaller jag. The patch, jag, and bore diameter all have to work together to get the right fit. I like a thick patch and smaller jag myself.

Some good photos would help if you can post them for us.

The main complaint I have with the TC's is the bulky stock. Phil fixed that nicely! All it needs now is some more conventional looking sights!

Could you rub a little charcoal in the carving to stain the grease?

Buy high and sell low. Make up the loses by doing a large volume. That's my theory. I still can't figure out why I ain't rich.

Plus it gives a person something to do when there is nothing much else to do. Many folks these days can't even imagine having nothing to do they're so occupied with their devices, like us on the forum right now. I could be out in my shop as I write this boning a ramrod, but here I sit. 50 or so...

I have a friend who has an original Le Page 14 gauge smooth bore. I can see the similarities between his and the OP's.

His tools sure do work for round balls. I have three of them.

Are the Lee bullets designed to bump up and fill the grooves when they're fired?

I've never used them since I'm a round ball shooter but I think that REAL is an acronym for Rifling Engraved At Loading which seems to me to indicate that they might be a little hard to get started, especially if the bullets aren't very soft. I wonder if a coned muzzle might be a "REAL" help?