Slowpoke: Assuming the bore actually measures .615, why don't you use the .595 diameter balls. You should not have a lot of trouble thumbing them into that barrel. ( please check the bore diameter, or ask Ed to check it, so you can order molds, or a quantity of lead ball to have on hand when the gun is finished. My .20 ga. barrel came out .622" , and I have a lot of .20 ga. wads I don't need. I bought 19 ga. wads and they work just fine. My gunbuilder had bought barrels from this same supplier on many occasions, and was using one of them himself. He didn't bother to measure the bore because the issue had never come up until we found the 20 ga. wads slipping down too easy in my gun. He was very apologetic, but I certainly was not going to demand he put a new barrel on the gun. It really wasn't his fault.)