We have an old saying in the Marine Corps, "It's not the dope on the gun, It's the dope behind it." I've personally found as long as all variables remain the same, powder, patch, ball, I've had no issue with accuracy. Semper Fi.I’m talking diameter not thickness here. I’ve read where the accepted view is that patch size doesn’t affect accuracy. What say you guys? I got out to do some shooting a few days ago: tc hawken 50 cal, 80gr by weight homemade black powder, .490 round ball, spit lubed pillow ticking. I cut some new patches that were much smaller and accuracy improved greatly. In fact previously at 75 yards I was lucky to get on paper. Now the gun is grouping very nicely shooting off hand.