Wow, didn't realize I haven't updated this thread in so long. Time flys when you're having fun they say.
The barrel has been replaced with a new one from Deer Creek. The barrel came with all holes drilled and dovetails cut.
I removed the sights from the old barrel and mounted them on the new one but, the wedge bracket was already installed. I had to shim both sights to take up the .007" to .008" gaps. The barrel has been coated with DuraBlue and it's a tough, good looking finish.
The new barrel is everything the old one wasn't. It's very smooth to load and it shoots very accurately. No more blown out patches.
I'm still working on accuracy but, it's producing groups less than 2 inches at 75yds when I do my part. I feel confident it will do better so, there's more work to be done.
I cast my first batch of .495" RB and shot a few yesterday (Friday) at the range. I weighed each ball and sorted them in to 2 groups. 1) 182 - 183 grains and 181 - 181.8 grains. They shoot as well at the factory Hornady swaged RBs I've been shooting but, they are very soft and easily damaged. I need to be more careful when starting them at the muzzle and need to be sure to seat them down the bore without pounding. Deformation makes for poor accuracy.
Fun, fun, fun! Weather is cooling down and being outdoors is getting more comfortable. I see many happy range sessions ahead for me and "Old Thumper" this fall.