I agree with Roundball on this. When you venture down to the .010" thick patching, you risk the patches tearing, or burning as they go out the bore.
Measure the Land to Land diamater( That is the high flat places in the bore.) Then look for a ball that is no less than .010" and better at .020" smaller than the land diameter. The difference between the land( Bore ) diameter, and the groove diameter, divided by 2 give you GROOVE DEPTH. That tells you how much thickness of patch is needed to fill that groove in addition to grabbing the ball and imparting the spin of the lands to the ball.
NOTE that wet or greased cloth patches tend to stretch or " compress ", so that you can use a cloth patch that is thicker than the difference between ball diameter and groove diameter.
For example, with a .540 Bore Diameter, and a .552 Groove diameter, you have grooves that are .006" deep. Use a .530 ball, and a .015 or .018" thick cloth patch, wetted, or greased, to wrap the ball. YOu need to come up with .552" in patch thickness and ball, combined. However, remember that the patch is going to contact the barrel on two opposite sides.
So, it works out this way. .540 minus .530 give you .010" of play between the ball and the lands. There is an additional groove depth of .006", or a total of .022" of area that must be filled. ( .010 for the land, and .006" for the groove depth times 2!)
Wrapped around that .530 ball, a .015" patch will provide .030" of fill for the space provided. But, in my example, This is only .008" thousands over the total width of the grooves, or .004 per groove on each side. That is an amount of Compression that is easily within the means of a wetted or greased cloth patch. In fact, I agree with Roundball to try the .018" patches, simple because your groove diameter will probably handle that thickness, too. The thicker the patch, the better the gas seal.
As to patch cutting, many guns have poor muzzle crowns, and its that fact that has the thicker patches being cut, at the muzzle, and makes it more difficult to seat the PRB. Try a 60 degree angle crown, and you should find seating the ball without damaging the patch to be much easier with the thicker patch.
Oh, I think you may be confused as to what is the groove and what is the land. When you look at the muzzle the lands are the raised portions of the rifling, and the grooves are the cuts between the lands. When shooting modern pistol bullets, for instance, its the lands that leave the " GROOVES ON THE BULLET" and the grooves in the barrel leave the high portions on the side of a bullet. Don't confuse the two.
I can't imagine a .54 caliber rifle having a true groove diameter of .542"ish". That would be grooves of only .001" on each side of the barrel. Notebook paper is .003" thick!
I suspect that what you measured instead was the land or bore diameter. Sometimes holding a caliper steady as you measure the land diameters gets a bit tricky, and its not unusually to see people give readins larger than what the actual size is. It takes a practiced touch on a caliper to get the correct measurement.
I demonstrated that fact to another member of this forum several weeks ago, when he brought his gun to my home to measure the bore. His bore was smaller than the nominal diameter for that caliber, explaining why he was having a tough time seating RB of the recommended size.
Best wishes. :thumbsup: