The " Secret" to better patterns with any MLer is to REDUCE the powder charge, not increase it. Most shooters are trying to duplicate Smokeless Powder velocities. Only the low end velocities can be reached, using BP. For the most part, BP loads are Sub Sonic. If you try to make them Super Sonic, you blow the pattern.
Consider these shotguns 30 yard guns, regarding patterns. Then, to get added "punch" at that range, use a larger size shot pellet, and more of it, compared to what you might use with smokeless powder. Increasing the amount of shot will make up the difference in pellet count that occurs when you go from a smaller shot size to a larger shot size. If you do Choke the barrel(s), on a BP shotgun, you can improve the Density of the pattern, but Not the velocity. Black Powder simply is not up to it.
Don't despair: The Commercial Duck Hunters on the Illinois River back in the 1880s used a lowly 2 3/4 dram load of BP behind a 1 1/4" oz. load of shot to kill ducks out to 50 yds. in their 12 gauge guns. That load is only about 1,000 fps. at the Muzzle. ( MV) [Once shot travels below the speed of sound( sub-sonic) it loses velocity at a much slower rate of speed than when its pushed out at super-sonic MVs.]
Most Smokeless powder loads that are supersonic lose all that velocity and become sub-sonic at about 20 yds., BTW. Look it up in the Lyman Shotshell Reloading Manual.
Using any kind of shot cup( Plastic, Paper, or Fabric) to protect the outer pellets in your load from rubbing against the bore, and getting flats, will improve your patterns, and improve the pellet count in the pattern. The Cup Does delay the opening of the pattern, and thereby gives it some "choke effect". You have to count pellets on the paper, both with and without some kind of shot cup, to see the improvement, but its there.
You might want to try putting a collar of card stock inside the cup of any AA plastic wad, to keep the shot column together that little bit longer after it leaves the muzzle. That will tighten the pattern some more. As long as the strips of card stock are cut the same width, the amount of tightening should be consistent from shot to shot.
The real problem using AA wads is that they are smaller in diameter than the bore of the shotguns, usually, and the wad and shot tilt as they are traveling out the barrel. If the shot column leaves the muzzle tilted, the patterns will be inconsistent down range. BTDT :redface: :shocked2: :idunno: :thumbsup: You might try using the shot cups sold by Ballistics Products for use with steel shot instead. I think you will get better results in a BP shotgun barrel. :hatsoff: