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Both rifles have GM barrels and cut patches for the first 100 shots or so. I remember lapping the bore with very fine grit in the flint gun before firing it the first time and it still cut patches. I think I had to give it another lap job with 240 grit before it stopped the patch cutting.Yeah, both my .45 cal match guns ( one flint the other underhammer percussion) with 1-60 pitch like the same ball diameter and patch thickness with a 65 grain charge of 3F.
I lap so many barrels it's hard for me to remember exactly what was done to each one after some years pass.
The percussion gun I think just stopped cutting patches on it's own after about a 100 shots.
GM barrels have deeper rifling than do TC barrels from my experience.
You might want to try some steel wool over a patch some folks talk about which has a burnishing effect on land corners. I've not done this but have heard many testimony's of it's effectiveness to reduce barrel fouling and stop patch cutting.I used the oversize patch and it was definitely snug. No small cut that I could find, and I looked close. I removed the barrel from the stock and scrubbed it with hot water and dawn liquid. Dried the inside and used JB bore clean and when finished with that, as directions, used JB bore bright. finished with a wet patch of ballistol, put a few patches over the muzzle to catch any ballistol that may run out. I'll go back to .440 RBs, going to start with a 50-grain load. I have OX Yoke precut, pre lubed .015 and .010 patches. The oversize patch showed that I wasn't getting the barrel as clean as I thought I was! I agree that adjusting my powder charge is one issue and I think I know what else I was doing that contributed to the blowouts. I'll know for sure my next trip to the range. Thanks for everyone's help