This is becoming more interesting.
From the encyclopedia Britannica:
"fustian, fabric originally made by weaving two sets of cotton wefts, or fillings, on a linen warp, popular during the European Middle Ages. The word has come to denote a class of heavy cotton fabrics, some of which have pile surfaces, including moleskin, velveteen, and corduroy.
...Switzerland had a rising fustian industry in the 14th century, and French weavers were making fringed and roughened fustians in the 16th. These early fustians appear to have been smooth fabrics with a soft raised nap; eventually, a ribbed pile surface was developed. By the 19th century cotton was being used for the warp as well as the filling.
In all fustians one of the sets of filling yarns is made up of floats (yarns that skip over two or more adjacent warp yarns). When a pile fabric is desired, the weft floats must be cut, a process originally performed by hand with a fustian knife but now done mechanically. The pile is brushed, sheared, and singed, and finally the fabric is bleached and dyed."
It would seem that this was some very thick and squishy patch material. Also, I found another reference that said it was the cloth used to make the clothing of the working class in England, I got the impression around 1834 or so, and it was stiffened, at the time of manufacture, with glue made from bone.
It would appear that some of the early military patching material was much thicker than we think ( or at least what I thought).
RussB might be closer to accurate with his Chamois Cloth (if it is not a synthetic material) than he thought.
Good going RussB. I can't wait to hear the report of how the Chamois Cloth works.
Also, RFD, I understand your point. I have the bad habit of wanting to squeeze the most accuracy out of my rifle that I can. I have taken it too far in trying to get a tight fit, thinking that was what was required for accuracy, to the point that one year the weather was cold (okay, for the PNW pushing single digits is cold) that I could not load my patch/ball combination... made for an interesting hunt
)