Hey Jimbo,
You're not wearing out your welcome and your questions ain't dumb. However, I may give some dumb answers. I'm certainly no expert about this weapon. I've studied a bit about it and have been blessed to own one for over 20 years, but I have a fairly limited experience in shooting live rounds from it. I'm just now getting serious about seeing just how accurate I can shoot with it. David and some of these long range guys can surely give you better advice and direction than I can, but I'll try to answer your questions the best I can too.
As for question 1, it does foul somewhat easliy and I have had a few rounds stick a bit, but that was due to me not being more careful in wiping the bore and not using enough lube on the bullet. If you are using cylindrical bullets, they need to fit pretty close to upset into the bore enough to seal against gas blow-by and engage the rifling. I don't know about the shooter being disqualified but I believe David answered that.
Question 2: It does have a noticeably heavier recoil than most ML rifles of that caliber. The bullet is heavier and the powder charge while not excessively heavy combines with that to create a pretty high barrel pressure. Also, the military style Whitworths are built on the Enfield musket pattern where the butt is more in line with the bore than is common in Springfield pattern muskets and sporting rifles. This tends to make the recoil more noticeable, but as David noted in an earlier post, it also makes the recoil more bearable when shooting at long ranges when the barrel is elevated several degrees above the horizontal. By the way, the bullets I shoot are 1 3/8" long. There were shorter bullets used, but not much shorter. Sir Joseph Whitworth said that it was his contention that great range with a low trajectory, accuracy and penetration are obtained by a long bullet, high rotation and a large powder charge. When he was asked to design the rifle which evolved into the one we're talking about, he was unrestricted in all but two things. He had to design something that retained the 530 gr. bullet weight and the 70 gr. powder charge used in the Enfield rifle musket. Actually, the recoil is not that terrible unless you do what I did and sit at a bench and shoot 40 rds. with no breaks except swabbing and loading.
Question 3: The hex molds are expensive and I will continue to use cylindricals which are said to be more accurate. One would think the opposite, but those who have shot both say the cylindricals generally perform the best. Possibly the hex bullets are more susceptible to wind variations, I don't know. Dyson's mold costs 150 Pounds and Kranen wants 220 Euros for his, so you're looking at over $250 U.S.
Question 4: Swaging .50 bullets to .45 is too much work for me. Seems to me like there would have to be some internal distortion that may make the bullet unbalanced. I have swaged .45/70 in the Whitworth mold and they were badly distorted on the outside. You can make a swage for this bullet in a lathe if you can get a proper sized reamer. I messed mine up so I need to make another. If you can buy a Whitworth swage from Dixie, Navy Arms or Gibbs that would be the way to go.
Fifty cents is a bit high for a bullet, but if they are hex bullets and you want to try some and if you have the money, that's an option. I've never paper patched, but would like to try sometime. The bullets I use have grease grooves. The hex molds made by Leon Kranen are available in both plain and with grooves. (Now that's a real weird looking bullet!)
As for your concerns about casual shooting and hunting I can tell you that it's not as casual as your run of the mill rifle or musket, but it's not that bad. One thing I failed to mentionn earlier is that I have started using a drop tube to load the powder. It keeps powder from sticking to a damp bore after swabbing and it slightly compresses the powder when loading. It's not absolutely necessary, so you won't need it for hunting. I've found that it makes it easier to load a tight bullet since the bullet doesn't have to scrape against powder stuck to the sides of the bore. I've hunted with mine and shot deer with it. With it's bullet weight and accuracy it would be an excellent choice in more open country and as long as you can see the game you're hunting well enough to make a clean killing shot, you can be comfortable at taking shots at a much longer range than with other muzzleloaders, especially RB guns.
1: I would stick with Black Powder and stay in the FFFg range. I guess I'm an old fuddy-duddy, but I've never used substitutes and as long as I get get BP that's all I'll ever use. If you feel comfortable with one of the others, by all means use it. The fouling ain't that much worse than any other BP gun, the problem is, the bullet fits much tighter than in a musket and also most shooters are used to firing several shots without swabbing. I swab after every shot in my flintlock rifle when target shooting as well as my rifle-musket. The only gun I don't swab every shot in is my Charleville, unless I'm shooting patched ball.
2&3: I have sized and shot some 45/70's (turned down in the lathe) in my rifle but wasn't too impressed. I need to shoot some more and evaluate more. If you can find a bullet of about .446-.447 diameter that weighs about 400-450 grs. and at least 1" long, you might have a keeper. There were quite a few variations of the Whitworth bullet. I would like to get some more variations myself. Also, if you can get a bullet with a shallow hollow base that would be good. That will form a gas seal as well as expand into the rifling. I have actually milled hollow bases into some of mine and they worked quite well.
4: If you get bullets with grease grooves you won't need to paper patch. I use a beeswax/Crisco lube that I use on my Minies and it works fine. After I grease the bullets, I run them through the sizer. As a matter of fact, after lunch I think I'm going to mill some more bases and lube some that I cast Thursday.
I've found that the Whitworth does take a little more care in shooting and cleaning, but I believe it's worth it to obtain the accuracy it's noted for. It is a rare piece of ordnance here and gets a lot of attention when it appears on the range or the reenactment field. I only wish that I could do it justice when I shoot it. Hopefully, I can get the sights fixed to suit my not so great eyesight and get a load worked up that will do the job. I hope you've gotten some kind of help here. I know that there are others who know a heck of a lot more than me about these things. I look forward to your underhammer thread and good luck with your rifle! If you have any more questions or comments feel free to post something. If you find anything new, let me know. I'm still learning too. :: I bet you wish I wasn't so windy, huh? :yakyak: