This reply is to everyone.
We can not be sure how tight the ball/patch diameter to bore diameter was in rifles during the 18th century and before the invention of precision calipers in the mid to late 18th century. This due to the fact that especially from the 18th century, the original ball mold is almost certainly missing and/or the bore may have been "freshed out" one or many times while the rifle was in active use. There is virtually no mention of short starters until around the percussion era, so that suggests they used a looser ball/patch combination than what we generally do today. So we really don't know how tight the fit of the ball and patch was to the bore size.
In 18th century accounts when they DO mention the patch, they often seem to be talking "generically" when they mention either a linen or leather patch. That does not mean that every rifle was loaded with either or both, but rather that both types of patches were used in rifles.
I know in the 18th century that there were rifles made with bores and oversized balls that had to be hammered down the bores, but we are not talking about that for most American Long Rifles.
Using the period tools and technology and understanding short starters were virtually not mentioned, it is very difficult for me to believe they used a ball size that was larger than .010" under the bore size and the ball may or probably was more likely .010" to .015" undersize (and maybe more, we just don't know). If that was true during the period, then it is more likely a brain tanned deerskin patch could have been used at times even when/if they normally used linen patching.
There are at least two cases where it was not only plausible they used leather instead of linen patches, but quite probable.
The 18th century Iron barrels had to be "freshed out" more often to a lot more often than our modern steel barrels. This probably due to the fact the Iron was not as tough as steel and/or some to many of the people were not as good about cleaning their guns. Once the lands were freshed, a bullet from a mold that was tight for a linen patch would have been looser to too loose. A brain tanned deerskin patch being a bit thicker, the rifle owner could still have used his original mold. More info on freshening barrels here:
http://flintriflesmith.com/ToolsandTechniques/freshening.htm
The Second Case for using a leather patch in a rifle would been had the original ball mold been damaged or lost and the owner had to use a ball or mold that was too loose for his rifle. IOW, the replacement mold was not "matched" to his barrel like the original mold was. So a thicker leather patch would have "saved the day" in the case where the ball size he had was otherwise too loose for his barrel.
Gus