First use a good caliper, or just use a set of inside dividers to determine the bore diameter. Then the general rule is to allow 1/100" gap on both sides, so subtract .020 from the diameter of the groove diameter. Then find a patch that is /015 or thicker, lube it with your favorite lube, and run the ball down the barrel. If its too tight, consider using a thinner patch material. If its too loose, try it to see how it shoots. Some old guns have some pretty open muzzles, and in the 18th century, guns had their muzzle coned to allow the PRB to be seated with a thumb, centered as it is pushed down on the powder. Typically, the coning did not expand the groove diameter, but simply reduced the lands( bore diameter) to groove dimeter. Coning is easy on both the patch and ball for seating, and you almost never get torn patches at the muzzle with a coned barrel.
Some older guns have deep grooves, as much as .012" for each groove. these can be difficult to find a ball and patch combination that works well, simply because its hard to find a patch material that will fill those deep grooves completely. measure the bore diameter( land to land) to give you an indication of proper ball size- .010" less than this land to land measurement, and then also measure the groove diameter. That will give you a better idea on how thick a patch is needed. In some cases, the only way you can keep from cutting patches is by using an overpowder wad, or filler. Traditional fillers were wasp nests, leaves including tobacco, milk weed tuffs, cotton, of course, raw hide or leather scraps, and fabric scraps, including wool, linen, muslin, canvas, denim, etc. If you use the cloth as fillers, you need to lube them or they will almost always burn and pose a fire threat to the ground in front of the muzzle. Nothing you can't put out quickly with the bottom of your shoe, but something to be conceerned about, nevertheless. Raw hide and leather generally are too tough to catch a spark and burn, while the loose fillers, including corn meal, blow out as the un-burned particles separate in front of the muzzle.