Smoothbore accuracy can be a here today, gone tomorrow type of thing if all the points already listed here, aren't adheared to.
: A further point about shooting from the bench for load testing is required. The gun must be held the same as it is when shot standing - that is, "in both hands", with the back of the fore-hand on the bags, not the fore-wood itself. It must be held in the hand and held tightly, to produce even the same size groups that offhand or kneeling can give. This gets back to proper bench strategy and bag-technique that the Bench Rest shooters are continually harping about, just that it's different for the ML in general, and very different for the flinters with big locks. It IS more than merely sitting down and llightly resting the gun and 'having at' the target.
: One high ranking observer in the 1830's described the 'then-curren' US military guns as having locks with fully 3 times the strength of mainspring they needed, and shooting way to much powder for accurate shooting or what was required for such close shooting on men as well as too-undersized, balls. For hunting, we require a bit more power than required to produce a fatal injury on a man, but for deer, certainly not the 165gr or even the 130gr. service charge of the 14 guage. In most of the large bore'd smoothies, a charge of 80gr. to 100gr. will handle most situations and for tight bush environments, even 60gr. to 80gr. will suffice. The lighter charges usually shoot more accurately than do the huge ones. This type of testing requires various patch thicknesses, perhaps testing with wads and, of course different powder charges. I would resrict the initial testing to the range I want for my maximum - NO SHOOT BEYOND - RANGE, then adjust that if necessary, but find the laod that shoots the bes there After than, re-test THAT particular load at closer ranges, and see if it suffices there. It makes little sense to work up load that shoots one hole at 40yd. but requires a bushell basket to hold the 90 or 100yd. group. I am certain that the load that shoots accurately enough at the max range, will indeed, shoot well for the same game at closer range. The reverse of this is unlikely.
: Rolling the balls with a rasp until large enough to fit, sounds like a geat idea. First of all, it destroys the windage, and secondly the cuts hold lube to help keep the fouling soft. It is a very good idea for those who shoot with wads, for sure.