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using mallets or hammers

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So the revolver is a bigger ball made smaller when pushed through the revolver barrel, but would not malleting the smaller round ball in a muzzleloading rifle, when coupled with a very tight patch, make it bigger? Just a tiny bit, but a few more thousandths of an inch of rifling contact might be what makes the difference?

You are not wrong. But, I believe, there not enough resistance to expand the ball, it will just slide down the bore. Unless it is grossly oversized. I often used a .457 in a .45 Douglas barrel and the balls did distort on loading to give a very tight, and consistent, accurate fit.
 
Currently experimenting with .600 ball in a .61 rifle. Muslin doesn't need a whacker but everything else does. Greased drill will load if I go Bruce Lee on the short starter. Reckon it needs about five pounds of lead through it before I get too excited.
 
I have one rifle that I load using a mallet. The stock was broken in half through the front of the lock panels and repaired. Using a mallet to seat the ball flush with muzzle puts a lot less stress on the stock than using a short starter. It creates a small flat on the ball about like a sprue on a cast ball. Accuracy is fine.
 
When using the patch tenderizer I grip the rifle behind the front sight and hold it up off the ground. Don't know if it helps but it makes me feel better.
 
That's always been my concern in using them. I've been resting the butt on my foot the few times I've used a mallet, but wondered if that was enough.
 
Yes, I also hold it up off the ground while using the longer rod of the short starter. I put it back down when seating with the regular ramrod.
 
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