You are beginning to sound like a very dangerous person to allow around guns. I hope i am wrong.
OF COURSE you cast the lead Balls out of soft, pure lead. A lead ball will expand in flesh at even very slow velocities. That is why they are way more effective than people believe, IF THE ONLY BASIS OF INFORMATION to the people is modern ballistics and modern bullets. Then there are the shills for gun companies, that actually both write lies, and travel around the country trying to get state legislatures to outlaw PRB for hunting deer, claiming that the round ball is ineffective to kill deer. They cite a bunch of data used and needed when shooting modern BULLETS with Smokeless Powder cartridges.
Apples and Orange.
Black Powder ballistics has NOTHING to do with modern Smokeless powder ballistics. Get that out of your head. If you want to get into shooting MLers, you need to learn an entirely different set of rules.
Now, a .45 cal. RB only weighs about 125 grains, and while it does put a .45 cal. hole in anything it hits, It does so very well at ranges out to 75 yds, depending on the load used. Its Not a good choice for shooting deer at 100 yds, and further, for a variety of reasons. Having said that, the caliber has killed lots of deer out there, in the hands of experienced shooters, who know exactly how to hold those open sights, to place the PRB EXACTLY where it needs to go to kill a deer.
Unless a deer is hit in the head, or spinal column at those ranges, its usually not going to drop dead in its tracks. ( Even with a modern HP bullet!). You are going to have to track the animal down. A good hit to the Heart/lung area, just behind the front leg, will give you a short tracking job in most cases.
Most Whitetail deer are shot, regardless of firearm, at distances of 50 yards and less, so the .45 cal MLer is a fine choice for most hunters. I shot one for years before having a .50 cal. rifle built for me, so that I could have enough power out at 100 yds, to take shots at deer at those longer ranges, and expect a quick kill.
About Patching material. Go to the top of the index page to this forum. Then come down to the " Member Resources " box. Scroll down to the line that says, " Articles, Charts and Links". Click on the word links and it takes you to a long list of suppliers of MLer stuff. Click on any entry there and you go to their website, and usually, to their catalog. Check out Track of the Wolf, Cains, October Country, Dixie GUN Works, Midway USA, MidSouth Shooter Supply, and any other supplier that might be located close to where you live. You will find great catalogs, and descriptions about patches, their thickness, whether you can by them pre-lubed, or dry, cut round, or in strips. If you go to a fabric store, take a MICROMETER or CALIPER with you and measure the thicknesses of their pillow ticking, pocket drill, and even any Linen they may have. The shops will usually sell you 1/3" of a yard( 12" by 36 inches) so that you can take the material samples home, WASH THEM and dry them, to remove the starch-like sizing from the fabric, and then try them in your gun with the ball you choose. If you are shooting a ".45", remember that these guns come in different bore diameters, depending on manufacturer. You can find ".45 " barrels that are .430, .440,.445,.451, .454, and .457" Its important then, that you actually measure the bore diameter of your gun barrel, to determine what ball diameter to buy. Most "KITS" will come with balls that are .440" diameter. That won't work if your gun is the smaller, .430". The .440" actually works bets in a barrel that is .451" in bore diameter. If the bore diameter is LARGER, you usually have to choose a ball diameter that is within .010" of that larger diameter.
To determine what thickness of patch material you should buy, you really need to know the GROOVE DEPTH of the rifling in your barrel. This is the distance from an adjoining LAND, to the bottom of the groove next to the land. That gives you an idea how thick the patch fabric must be to fill that groove. The lands will compress the fabric as the ball is loaded, and the excess fabric will squeeze to one side or the other to stuff down into the grooves next to each land. You want a tight fit in the grooves to seal the grooves from burning gases from the powder charge behind the PRB. Otherwise, the hot gases burn the patch, tear it, cut, or melt, the lead ball, and accuracy goes SOUTH in a hurry! We lube the patch to help it stretch a bit, and to grease the bore so that the powder fouling left in the barrel after the PRB leaves the muzzle stays soft for easier cleaning.
I hope you know someone, or can find a local BP club where you can find folks familiar with these guns to keep you out of danger. There are lots of different safety rules for you to learn. Its not rocket science, but you have to pay attention. Good Luck with your new gun. :thumbsup: