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Leadriver,
I fought that same battle years ago with .32 Dixie Southern Mountain Rifle. I could not make it shoot well after the first or second shot. I did most of the things you did to try to figure it out. The lube changes and patch thickness, all of that. The trouble with some small caliber rifles is the fouling builds up so quick that pressures change and point of impact goes all over. Just like you, I settled on swabbing the bore every two shots max when Rock Chuck hunting and was successful. My little rifle just will not shoot a string of accurate shots like my larger caliber rifles will without swabbing the barrel.
Old Shepherd
 
This will be a hunting gun. I wanted a lube that could stay in the barrel. I don't have to swab between shots but accuracy isnt as good as when i swab every 2 shots. Mink oil is pretty well regarded as a good lube.
Consistency. If fouling builds while shooting (and it does,) then without cleaning, consistency goes out the window. If we can shoot a particular plural number of times without cleaning and we actually do that, we can't say we are being consistent. The most we can say is that we can load and shoot just fine without being consistent. No muzzleloading authority will advise us to not be consistent. Just semantics? Me, I've been swabbing between shots since the very beginning, except maybe when needing to move immediately after firing but I can't remember such an occasion. M/Ling to me is a very non-tactical activity but I know that some arranged shoots might involve immulation historical battles. I mean time spent swabbing for me, likely feeds my OCD I have related to shooting consistency, just like end of session cleaning. I can't be finished until that last white patch comes out as clean as it went in.
 

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