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I believe you nailed it Zonie and thanks for your input.

With patches that shot well, the primary difference was 'one loads harder than the other'. Otherwise, seven shots fired with patches of both thicknesses shot into just over nine inches at 200 yards- including a flyer. It makes sense that a perfect ball will fly truer than a deformed one, and the thinner patch did shoot a little better than the too-thick one. But the fact remains that the groups overlapped at that distance, which tells me that 0.010 variance wasn't even changing the POI.

The few patches I found were just 'donuts'. I think I'll be standardizing on 0.010 patch material bought bulk, and just lubing what I need for a day's shooting. I never fiddled with ready-made patches much and I can get along w/o them just fine.
 

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