Flinch, if you're going for historical accuracy most of the 18th century guns had longer barrels, in some cases over 50 inches long. In my limited research 42-48" seems to be the norm with exceptions going in both directions. I have two .62 cal. smoothbores right now one is a true fowler with no rear sight or cheek peice with a 42" barrel. I got a nice pattern at 25 yards using #6 shot. My load was 70 grains of 3f with about 1 1/2 times that amount of shot with some leaves stuffed in for wadding. Using more modern shot cups, wadding, ect., like Rebel said will definatly improve your pattern. Oh yeah where was I going with this, my other smoothie is a smoothrifle, has a rear sight and cheek peice, looks & handles like a rifle but with a 44" getz oct. to round smoothbore barrel. I haven't used shot in it but what I am attempting to get at is neither barrel is uncomfortable or hard to manuver with. At any rate let us know what you decide to build. Good luck :m2c: