As I mentioned, with cloth patch, use the .595 ball or perhaps the larger .600 from the cheaper Lee mould. A .595 ball will allso another 3 thou or so of material to hold more lbricant and hat makes seating easier. As stated, the .610 was suggested for use with paper ctgs. as they were the issued ammo for the various Military muskets. Now, the military was interested in prolonged shooting without any tight fitting ammo. That's why they (American & French) issued .64 balls in paper ctgs. for the .69's Muskets and the English issued .69 and .70 cal. balls for the Bess's much larger bore, being .75 to .77.
: Paper cartridge accuracy is much better with a tighter than Military fit, so I suggested the .610 ball. One wrapp of typewriter (printer) paper is appox .003 per side. That's .006 on the sides of the .610 ball, giving a .616" fit in the .620 or .625 bore. 1 1/2 wrapps comes out to .619". Dip the ball end of the paper patch in melted lube, quickly, sit them bottom up, and the excess will drain and harden. This will help soften the lube for extended shooting without contaminating the powder charge.
: I wold use a BP lube for this, not ALOX, which is for smokeless powder.
: Insidently, all of the guys I shoot with who use .54's, use a .535 ball and .015 denim patch in their rifles. They all use 3/8" wiping sticks for loading & none use mallets. Almost all of them do shoot .54's, as their match rifles are the same ones they use for Moose. .54 is generally the recommended RB for Moose up here. They can be taken with smaller balls, but he range is much closer. A well loaded and accurately shot .54, will do for up to about 125yds on moose.
Daryl