Jack: There a lot of variations in bore diameters on the replica( as well as originals) Brown Bess smoothbores. To get the best accuracy, you need to know the actual diameter of your bore. If you then get a round ball that is approx. .020" smaller than bore diameter, and use a lubed patch that gives a snug, but not tight fit, you should be able to get reasonably good accuracy out to 50 yds using Black Powder. The front sight being a wide bayonet lug, and the lack of a rear sight are impediments, but can be overcome. Some shooters file grooves in the tang infront of the tang bolt to act as windage marks and a rear " sight ". Some just set the slot in the tang bolt so that the slot runs in line with the barrel, so it is used, in the bottom of your peripheral vision to help aligned your eye with the barrel, and cheek on the comb of the stock. Just that can reduce group sizes from 8 inches to 4-5 inches at 50 yds.
Most shooters are using .690 cal. round balls in their besses, with a cloth patch. Some use larger balls, but they don't always tell us their bore sizes. The round balls weigh an ounce or more at that diameter, and it does not take much powder to drive those fast enough to kill a deer. 70 grains of FFg is a place to start, with charged down to 50 grains for target shooting, and even less for informal shooting. Because the ball weighs so much, there is little point in trying to burn lots of powder behind it. I would not exceed 90 grains, just because recoil is going to become a factor, while producing very little extra velocity or down range energy at distances over 50 yds. I know some bess shooters who can shoot one hole 5 round groups off a rest at 50 yds, and shoot 5 round groups of 3 inches off hand, so some of the guns made for that kind of shooting are very accurate guns. Remember, a three inch group means your ball is hitting within 1.5 inches of the Point of Aim( POA). Since the ball is almost 3/4 inch across, that is very fine shooting for a gun with no rear sight.