So where did that Justin go anyhow?
Yes, if a bullet does not stabilize, due to the rate of twist being too slow, a SHORTER bullet will usually do the trick.
Groups opening up that much does sound like the bullet is not stable. (but it could very well be a sighting problem...can the shooter hit well at 100 with another rifle of known good accuracy?) It sounds like how a smoothbore shoots, real good at 50, but then real "big" at 100.
Yes, what are the powder charges? The "trend" these days is towards 150 grain mega-charges of powder...100 grains in a .54 should be more than enough to drop an Elk under 100 yards. A too heavy charge could be skidding the slug over the rifling, and not giving it much spin.
I like the combined advice of limiting range to 75 yards in the short term, and then getting a round-ball barrel for a long term fix. Leave the sabots for the in-line shooters and the slugs for the rifle-muskets.
If slugs are a must for some reason, indeed try a shorter one, and start it out over a light charge, and slowly work the charge up until accuracy falls off.
Rat