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I would think that the compromise between ball diameter and patch thickness would be to still have the ball to show a thin band of cloth weave marks embossed into the ball.  The width of the cloth marks will also define the effort required to start the PRB into the bore.  I usually use a small light 8 ounce dead blow hammer on the ball starter tool to save wear and tear on my fist.

I still want a fairly snug fit to reduce gas blow by as much as possible within the PRB fitment compromise.

Also a felt over powder wad helps to reduce blow by and patch burn through particularly with thin patches.


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