Round ball, patch thickness relationship

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Lets dig into your ? overall & come up with things to ponder. A .510 ball leaves alot of empty space to fill. A thin patch thickness or patching of frugal buying may not hold up under your powder load. Many barrels have a standard bore of from land to land of the .540. Now not all have the same groove depth you have to fill up with the patching. Some barrel makers use a groove depth as deep as .018, while some may go with button depth of .004 to .006. Not all barrel makers give a nice smooth groove cut. Will be sharp edges & burrs. So thick patching maybe cut as loaded until the land/groove edge gets polished smooth by the patching. You can polish & or lap the bore to smooth it quicker.
 
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