Well, I just finished spending nine hours at the range today; after spending about six hours each, Friday and Saturday. Things are finally beginning to come into focus.
I contacted Rice Barrels and confirmed that my grooves are .016 - .018 deep. I've found that while I can shoot a few loads with a .440 ball with fairly good results, so far I haven't totally eliminated burned patches with this ball size.
I also went to Hobby Lobby and found some decent patch material with a thickness of .024".
I talked to an experienced muzzleloader at the range who said he had never been able to get satisfactory results using commercial prelubed patches, so I'm now lubing my own, starting with Mink Oil. He also confirmed that we do have a gentleman who shoots at our range, he actually drives out of Houston, who is one of the two or three best shooters in the U.S. and who has won the National Friendship Championships, I think he said, five or six times. I know I have the spelling incorrect, but it sounded like his name was Steve " eee-fert" - Effert. Perhaps someone may recognize whom I'm referring to.
Anyways, the results of this long weekend of shooting is that I'm zeroing in on a 55gr or 60 gr powder load, using a .445 ball. And although a .020 patch will produce some excellent results, it looks like the thicker .024 patch will give consistently better results over a wider range of loads.
The single best result I've yet to achieve with my gun was with a .445 ball, 60gr of Swiss 3F, with my own patch I'm calling HL024, and Mink Oil lube.
My next rounds of shooting will be to try the same loads with Bumblin Bear Grease, Bore Butter and Young Country Lube.
What looks like a good short term/temporary solution, to insure I'm ready to go the second weekend in January, when our monthly shoots resume, is to go with the 55 gr powder load, if I can consistently duplicate today's results, and to simply adjust my sights horizontally without any filing for vertical adjustment. I'll have to see how high I am at 25 yards and will have to just be satisfied with being low at 100 yards, until I have time for other adjustments.
But I'm satisfied with the progress I made this holiday weekend.