Funny, I've read where folks "chewed" ball by applying a farrier's rasp to them and rolling against a wooden board. Some folks thought the ball was like a golf ball in flight, BUT a golf ball has rotation, just not along an axis oriented to the flight path.
Another idea was to do something very similar to Britsmoothy…
It involves some .760" ball I happened on and I use a leather punch to shave enough lead so they load .
What they did is they "dimpled" or "chewed" large sized ball, such as .735...but when there were bits of raised lead on the surface of the ball..., they just fit within the bore (.75), but with very little friction as it was a very small amount of lead coming into contact with the barrel wall. They were just a tad snug, needing a little pressure, and
these shot very well, it was reported.
Now .690 I've used in plastic shot cups in my 12 gauge, to make a "punkin' ball" load, PLUS....
We found when shooting Goex 2Fg in live rounds, that if the shooter (in Maryland with June humidity) was to shoot all 24 cartridges from his box..., the musket ball for the Bess had to be
.675 - .678.
Now some caveats with that test..., it was five fellows. A mixture of Pedersoli and Jap Bess, all checked to be .75 bore. Five pounds of GOEX from a single lot of the powder. We found that with the .690 ball, two of the five shooters were able to finish the box, and all of the five had to start to load the last few rounds "bare", without any paper wrapped around them, due to fowling. Three of the five got roundballs stuck. (So we had to clear those to continue) The next size down offered for sale was .678...but a couple of the guys had gotten .675 instead when we checked them. So we shot both. All 24 rounds from all five muskets, were fired in volley, no problem. We did notice both times as we neared the end of the box..., accuracy improved. So.., I can't say that a .685 or .680 ball wouldn't work as well, since we didn't have any to test.
So I see that Track is offering .750 cast round ball...and I have a small section of the end of a Bess barrel, that I use along with a small piece of an octagonal rifle barrel, that I show tourists at historic sites when explaining muskets and rifles..., maybe I should get some .750 and
swage the ball like Britsmoothie.
LD