Dave, et.al.:
Thanks for the additional input, though the recommendations are somewhat contradictory.
I was hoping someone would have a historical reference on the original specifications as stated by Ferguson, himself.
My own experience with undersized bullets in any rifled arm is that they simply don't shoot as well as full groove-diameter bullets.
I am willing to concede that heavy, cylindrical bullets will slug-up ahead of a suitable charge of BP, but have proved to my own satisfaction that full diameter bullets shoot best. Roundballs have the shortest bearing surface of all bullet types, less mass forward of the bearing surface, and are unlikely to slug-up under any circumstances. The excess windage not only permits severe escape of gas around the ball, but also scouring of the bearing surface by molten powder residue solids (remember that more than half of the combustion products of BP are solids).
Then, too, it seems significant that screw-barreled breechloaders used a full-diameter or slightly oversized ball.
The Rapine mold which came with the rifle casts a .650" ball, and the Lyman is .648:- I really think that such bullets MUST shoot better than any undersized ones, and am going to work with them until convinced that they will not shoot.
Thanks again, all;
mhb - MIke