Reducew your powder charge. See V.M. Starr's comments in Bob Spenser's Black Powder Notebook.
[url]
http://members.aye.net/~bspen/index.html[/url]
You should also reduce the weigh and thickness of your cushion wad to help the wad fall off the shot after it leaves the barrel, instead of following the shot, and punching a hole in the pattern.
Some shooters have begun making their own cushion wads out of styrofoam using a patch cutter. They are lighter, do not hold lube, and drop away shortly after leaving the barrel. Because of their soft texture, they provide a good seal, will hold lube wiped on their edges, and then leave only a minimal amount of debris in the barrel. They are not accepted in formal shooting contests under NMLRA rules, but they work great in the field.
Finally, there is always jug choking your gun, where a cutter is inserted in the muzzle to cut a shallow expansion chamber in the barrel, so that the shot column first expands, and then is contracted just before exiting the muzzle.
I am still playing with paper shot cups, so I can't make a recommendation there, yet. However, I think these may result in some improvement in patterns, based on what I have seen to date.
I think the best thing shooters can do is not expect a black powder shotgun to be taking targets at 40 yds and over, particularly if it is a cylinder bore gun. With choke tubes, or even jug choke, you can get good patterns at those distances, but today's modern shotshell is the cumulative result of all the years of research into black powder ballistics, and then smokeless powder ballistics. They also use plastic shot cups to protect the shot, and buffers in the shot in some " long range loads ". Black Powder shotguns are fun to use and shoot because they do impose extra burdens, like not reaching out as far, or performing as well with huge charges of powder. Remember, Smokeless powder burns up complete within a few inches of the chamber, and the pressure from the expanding gases have the rest of the barrel to diminish. With Black Powder, the burning occurs for the length of the barrel, and only when the wads and shot leave the barrel can the pressure ebb significantly. The benefit of this gradually increasing pressure is that the shot is not deformed by a sudden jolt when the powder ignites, and round shot tends to stay in the pattern, where deformed shot in modern shotshells routinely drops out of the pattern in the first 20 yds. So, getting the most pattern for your effort involves a few different considerations than you might use in reloading modern shotshells using smokeless powder. The secret to killing game at the edge of a BP shotguns effective range is not more velocity, but the next larger size shot. The weight of each pellet that stays in the pattern then delivers the kind of energy needed to take down a bird.
In my 12 ga. S x S double shotgun, for instance, I use a 2 3/4 dram load of FFg, powder, and 1 1/4 oz. of #5 shot for pheasants. I have killed them stone dead at 35 yds with that load. Most of my kills are at less than 30 yds, where the load shines. The slower charge of powder happens to make a very nice pattern. With paper shot cups, I am getting some indications that I might increase my patterns to Modified, or 50% at 30 yds. I am now trying to see if I can get any more out of the cups, or if I will have to be satisfied with just that. For instance, I was putting a full 20 ga. cushion wad in the bottom of the shotcup. I intend to use only half a cushion wad in the cups to see if that won't improve the pattern even more.
You might pattern your gun using modern 20 ga. plastic shotcups. They may not be kosher by NMLRA rules, but if they improve your performance in the field, use them.