All barrels are different, I had a TC Renegade that would shoot a cloverleaf with any patched ball charge, I have also had TC guns that wouldn't group well with anything, all were bought new.
I had a sewer pipe TC barrel bored from .50 to .54 by Bobby Hoyt, 1 in 48, .012 round bottom rifling that is amazingly accurate with a patched round ball. I used 75gr of 2F, a .530 ball and .015 ticking, it just about put them in the same hole at 50 yds so I didn't try anything else. It was a friend's gun so I handed it back to him with the right components, told him how to clean it properly and sent him on his way. He killed three deer with the rifle last year.
Eric, FWIW: being a longtime fan of the lowly Renegade, mostly because of the overall design, but especially because of the butt stock design, I have experienced the exact same thing.
Don't get me wrong, I love the looks of the "Hawken or Plains Style" rifles, and I still have a few, and still shoot 'em every time I get a chance, it's just that I simply feel more comfortable behind the shotgun style stock of the Renegade, and the semi-look of a English Sporting Rifle is very pleasing to my eyes, but that's just me.
Anyway, I've gone through
a lot of barrels over the past 60 plus years of shooting Muzzleloaders, and,.....for no reason, that I was ever astute enough to see, some barrels shot very well, while others just didn't shoot as well, no matter what I tried.
I spent a lot of years "spinning my wheels" doing my best to make 'em shoot when it just wasn't there.
It would likely be more accurate to say that while most have shot "pretty good" by many standards, a few of the others were simply outstanding, while using the same cal., same load, same patch, same lube, same seating, same, same everything....like I've always said, I was spinning my wheels because I could not accept the simple fact that two exact looking barrels were still just a wee bit different somehow.
So, Just like you said,
ALL barrels are different!
Even on consecutive serial numbered rifles, one barrel will truly shine, while the other not so much...go figure!
It is often said that every barrel ever made is a Science within itself.
The older I get, and the more experience I get with the lowly T/C, the more I believe in that statement.
Uncle Russ...