Patch is too thin or ball is too small, or both. 70 grains the accuracy is good :hmm: , use a .015 patch & a .535 ball & accuracy will be awesome. BUT it will most likely be harder to load.
But 70 grains in a .54 cal rifle is plenty to kill a whitetail deer. I have killed ? 4-5 a year for the past 13 years with that load. You might find that same load in 2F even more accurate. The 2F will burn a lil slower & less pressure upon ignition. My best accuracy in mine is actually 65 grains of 2F.
But it sounds like you are blowing up the patches with the 80 grains of 3F. When you increase the charge you also increase the pressure against the patch seal & you are getting blow-by...... thus for a heavier charge you need a better seal, = thicker patch or larger ball on a .015 patch. Bad blow-by will turn a cotton patch into a wad of lint.
When I go work loads on a rifle, I usually take a .010 & a .005 under bore sized ball, and about 6 dif patch thicknesses & 3-4 dif. lubes. Always One of the combos is outstanding to all the rest, and then I start working that down. Almost Every Single time the most accurate ball is .005 under bore size & on the load side of a powder charge.
Keith Lisle
PS: Don't do Anything to the barrel.... Just shoot the H out of it, clean it well, dry, lube it. The barrel is not the problem. After 200-400 rounds you will have it all figured out.