Good Morning Fixit,
Since Rabbitt has thrown my name into the mix, I will offer my advice on the breeching question.
To begin with, I will throw the bacon grease into the fire and state that I do care what standards were used by the old timers.
My work is machined in accordance for today's standards of safety. The standard for MINIMUM HOLDING STRENGTH of a threaded fasterner is the length of thread equal of the diameter of the thread.
Now specifically to your question. If your barrel size accoss the flats is 15/16" or 1", a 3/4-16 TPIwould be the proper size. In the case of a 15/16" barrel in 45 caliber, a 5/8-18 TPI would be satisfactory.
The Thompson-Center folks use a 11/16-20 TPI size which is in the neither the NC nor the NF standardardized thread family, but is in the standardized SPECIAL THREAD SERIES.
For my part, I like the 11/16-16 TPI NF thread for most (but not ALL) 15/16's barrel breech jobs. Caliber or bore size is also a prime consideration in selecting the appropriate breech plug size.
It is impossible to tap a complete thread to the bottom of a blind hole or the breech of a muzzle loading loading rifle. the end of the breech plug threads will have to be relieved from one to one and a half thread length. This means that the MINIMUM holding strength has been reduced.
To compensate for this, make the breech plug thread 1/8" or 3/16" longer or even a 1/4 inch longer.
The longer breech plug will not be a problem even with a shorter hammer throw. The end of the breech plug can be pre-drilled for a short powder powder chamber. It is best to finish the powder chamber with a ball end mill of the same diameter as the twist drill. This will give the end of the powder chamber a very nice, professional finish and appearence.
The barrel can then then be drilled and tapped through the barrel AND breech plug at the vary end of the powder chamber.
A good machinist can even taper the powder chamber to form a Nock type of powder chamber.
And by the the way, instruct your machinist to BORE not DRILL the breech to the correct tap drill diameter in order to form an internal square shoulder for the end of the breech plug to mate against.
If he tells you this is not necessary or worth the extra trouble, find yourself another machinist.
The part of the breech plug that fits in to the under hammer action does not have to be the same diameter as the the breech plug thread.
These are my personal views on breech plug safety, and I will not engage in a debate on that issue.
Best regards and good shooting.
God and Texas
John L. Hinnant
If you are not an NRA or NMLRA Member, why not? I am carrying your load.