tg- No, 120 gr of powder in a .54 ain't passing the point of diminishing returns. But more powder kicks a lot more, and there isn't much practical gain at ML ranges, say 100-125 yards. To put this in perspective- Lyman Black Powder Handbook, 1975, shows loads for a 30" .54 cal test gun. Top load was 160 grains of 3F G-O powder with a patched .535 ball for 2,072 fps at 14,710 CUP (pressure). A 43" barrel gave 2,158 fps at 15,000 CUP.***Lyman BP Handbook & Loading Manual 2nd Ed, 2001, shows a .54 cal. barrel 32", 1/60 twist with a .535 ball and a max load of 120 gr Goes 3F at 1735 fps and 8300 psi AND a max of 120 gr Goex 2F at 1803 fps and 8300 psi. Of 193 .54 cal combinations of different barrels, powders and projectiles, 56 have maximums between 17,000 and 29,100 psi.*** The original Green River Rifle Works 1978 price list recommended their barrels be PROOFED with a single patched round ball and 2F powder. Charge for .54 caliber was to be 210 grains. Then the recommended MAXIMUM LOAD was 175 grains of 2F, to give about 2,000 fps. Note that this was their barrels, no longer available. Even Dr. Gary White, who owned the business, used only 150 gr of C&H black powder and a .526 ball at 1860 fps in a Leman Trade Rifle to hunt Dall sheep. Shot one in the neck at 50 yards and it ran off. Had to chase it and shoot it in the lungs at 150 yards to kill it.***The max load for .45 cal was 110 gr 2F, for .50 cal 150 gr, for .58 cal 200 gr, .62 cal 260 gr and .69 cal 300 gr, all to give about 2000 fps. I remember one GRRW employee at a match, shooting a .69 GR Hawken. Don't know what his load was, but the recoil turned him half around. Don't remember he ever hit anything. I was tied with Doc White in the finals of this match, using 35 gr 3F in my .45 Leman Trade Rifle. When we got to 200 yards, I doubled to 70 grains, didn't know the drop, and somebody beat us both.*** I'll come back later and give some of my test results.