Patch size?

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It doesn't have to be perfectly flush with the muzzle. Any excess can be rammed down with the ball.
 
Smaller balls like the 32 when the patch is bigger it tends to grab the RR when pushed in because there isn't much room between the bore and RR. Just a minor detail, just pull the rod back out a little and it pushes the PRB down from on top of the patch folds.
 
There is no need to be concerned about a bit of excess patch material. Square patches work as well as round or cut at the musket. You do want to be sure that your ramrod is on top of the patch and ball. Be sure you patch has a bit of lubricant so that the fouling can be pushed out of the grooves and down to the powder.
 
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