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Pedersoli lists a .435 ball for the smoothbore and a .445 for the rifled version. Doesn’t amount to much difference. Personally I’d just go with the rifled version unless you have some smooth bore competitions on the menu.

I'm in the 1 1/2" 50 yd and 3 1/2-4" 100 yd from a bench crowd unless I go all out for the smallest group possible (like when I'm adjusting sights). Then its more like 1/2" at 50 yds and 2 1/2 to 3" at 100.

"The individual I spoke with at the NRA (name withheld deliberately) stated that flint gun accidents are about 6x more common than when shooting percussion or in-lines." First time I've ever heard that one. If you can't come up with a good argument then just make up some statistics and use...

The pressure cooker is your friend when it comes to these cuts.

Would have been helpful if you had stated that in the original post. 6" groups, offhand one handed at 10 yds isn’t a very good group. But we have no idea if its you, the pistol, the load or some combination of all the above. Kind of a non-sensical question.

You asked what the group considered to be reasonable accuracy from a brand new flintlock pistol. I told you my expectations. Shooting one handed without benefit of a rest tells you nothing about the pistols accuracy. If you're asking about what I would expect a first time flintlock pistol...

Just starting out with a brand new pistol, from a bench rest, I’d be reasonably happy with 2” groups at 25 yards. Further load development should cut that in half

I've run into people shooting pyrodex in their flintlocks. Offered them some real BP but they swore they didn't need it because "Pyrodex works just fine in my rifle". After shooting side by side with my rifle shooting real BP the difference was readily apparent and they wanted to try the real...

I shoot trail walks and bullseye shoots, mostly with my flintlocks. Use the same loading technique for both, spit patch, no wiping, what many would consider a "loose" ball/patch comb. I usually spend the last 15 minutes of a 30 minute relay smoking my pipe waiting for everybody else to finish...

Or you could Knapp with something that doesn’t spark like brass.

Does your lock have a fly?

Upper picture is back when I was adjusting sights on my .54 Mortimer, trying to get the fixed and leaf sights where I wanted them hitting. Three shot cluster at 50 yds was 1/2" CTC and 100 yd group was 2 3/4" CTC which turns out to be pretty typical for this rifle from a bench given ideal...

.562 ball in my .58 Colrain Barrel, .530 ball in my .54 Colerain and Pedersoli Mortimer barrels, and .318 ball in my GM .32 all with the same drill patch material that measures around .018". Ranges from not quite able to start with my thumb to needs a short starter for sure. No hammers or...

Mine finally arrived last week. Not seeing any of the issues listed above other than the tight wedge. Chokes measured as advertised. Did a quick pattern board run to make sure things were reasonably well aligned. POI at 25 yds seems to be 50/50 for me. Shot some easy 5-stand targets, including...

According to UPS, mine is stuck somewhere between Tennessee and Oregon due to a severe weather delay. Once it arrives we can compare notes.

Blasting away at the same target presentation over and over gets pretty boring or frustrating, depending on whether you're hitting or missing. It can also slow things down as every competitor has to wait for that one station. You don't need a lot of traps to create a variety of presentations...

Sorry, I was replying to the OP, not your post.

I assume you're talking wing shooting clays vice a trade gun type trail walk. The ones I've been to have been based on a 5-stand type setup. Lets people stay in the same location so they can set up a small loading table to keep their supplies on. The score keeper(s)/trappers have to stay on...

Your numbers indicate a variation of over 1.5% in the weight of a ball. Whether that is significant is up to you.

Weight variations are common. As you found out the early casts tend to be problematic as the mold probably isn't up to temperature. I weigh mine and use +/- 1 grain as the determining factor for my large calibers. I use the rejects for non-critical practice like shooting 50 m. chickens on the...