Cerrtainly this would be something to check out. However, most of the .54 cal. barrels I have seen are pretty stout, compared to those I sometimes see on muskets, and .58 cal. guns. I think it would be highly unlikely to find a bulged .54 barrel today. And, You would feel a " give" when running a thight patch down the barrel when cleaning, if there is a bulge down there. I think changing to FFg powder may work, but one way or another, using either an overpowder wad, or card, or using a coarse filler like cornmeal, will save that patching. I do like the idea of using leather for patching, but unless you use a tanned hide that has been put through a cutter, and thinned, the thickness of the hide can vary considerably from the flanks to the belly, to the back. And, I hate to waste a good deerhide for patching. I never seem to have enough scraps after a project to make many patches, either. Just my $.02.You rmileage may differ.