I'm trying to find a 15/16" Octagon barrel in 12 ga. for my new underhammer. I would like to have it as a bird hunting barrel. Anyone have one or know where I can find one? I figure I can have another breech plug made to fit my Underhammer.
I've got to agree with the others 15/16" doesn't leave nearly enough breech thickness to have a healthy margin of safety.
I wouldn't go over 28ga (approx. .55caliber), and that would be my uppermost limit. So, even your 20ga idea wouldn't be safe (in my estimation).
I think a lot of times when people are considering a muzzleloading 12gauge swap-in barrel, they immediately start comparing the thickness to a modern 12ga barrel, BUT it's "apples & oranges"--the steel used is completely different, and the pressure curves also.
IMO, I would want 1 1/4" across flats (or O.D.) at the breech for a 12gauge barrel, and probably 1 1/8" for the 20gauge.
Those larger barrel sizes may look somewhat "out of place" relative to your receiver and to the original rifle barrel's thickness. When it's a matter of (my) safety VS (the gun's) aesthetic beauty--my safety is ALWAYS FIRST!
BTW, my 15gauge smoothbore flint gun had a barrel that was
1 1/8" AF at the breech--I still always felt the gun could have stood a heavier breech though...
Back when gun barrels were made of iron, damascus, or very poor quality steel; most people decided that a "SAFE" barrel should be TWICE the thickness of the ball it used, and that was a good "rule of thumb".
Nowadays, if we could know exactly what kind of steel every barrel was made from, we could get away with thinner barrels. BUT, most barrels are still made from low carbon & mild steels (read that as cheaper to use!), so we probably ought not to take chances.
I still think it's a good idea (though maybe not very practicial) to make every manufacturer build their barrels thickness at twice the diameter of the bore. I just don't want anyone (especially me!) to get hurt needlessly.
ALWAYS use a BIG enough gun, and shoot safely!
WV_Hillbilly