Years ago I had Waksupi (Ric Carter) build a Chambers Isaac Haines .54cal. rifle for me. (He did a very nice job, btw.) However, I had to work hard to find a ball diameter and patch thickness combination that would produce the accuracy I was looking for: 1" groups @ 50 yd. My Lyman/Investarms .50cal. Great Plains rifle will generally do that if I use a .490 Lyman RB (.488" in fact) with a .018" pillow ticking patch, but not the Isaac Haines. Trust me, I've tried, usually varying the patch thickness from .017" -> .024" using either a Jeff Tanner or RCBS .530" - .531" RB mould as their droppings are identical. Varying the powder charge didn't have much effect either: I never found the "sweet spot."
I've also been using the IH in Ohio Joe's 50 yd. postal matches on another forum (5 offhand shots + 5 from a chunk at 50 yd. at a target measuring 11" x 14", with an 8" square central black section, and a 3" square bullseye), but I've never scored more than 37- out of a possible 50 points. In fact, my last two match scores were only 32/50. Having had enough of such nonsense, I thought I had nothing to lose by trying a larger, .535" RB with various patch combinations.
Today I put the above .535" RB (.537" in fact; Lee Precision mould) theory to the test. The load, incidentally, was the same as I've been using in Ohio Joe's postal matches, namely 80gr. Diamondback FFg. Patches, as always, were lubed with 1 Ballistol : 6 water and were just shy of dripping wet. All shooting was done @ 50 yd. with front and rear rests. First up were .014" thick pillow ticking patches, which loaded easily, but which produced only a 3/4" (i.e., 2 touching) x 3 3/4" 7-shot group. I next tried .018" pillow ticking and was pleased to see some progress: 7 shots went into a 1/2" x 3" group with 3 in a 1/2" x 3/4" cluster. Both patch thicknesses allowed easy starting and seating. Lastly, I tried what I think is muslin fabric @ .021", which works OK with the .530" RB's, but was much more difficult to start and seat than the other material. Accuracy wasn't all that good either with 5 shots landing in a 1/2" x 5" group. Why only 5 shots? Because the sun was on my sights and in my face and I had difficulty seeing the target.
All in all, it was a good range day as there was little wind, low humidity, and pleasant (58 deg.) temperatures. However, our range is arranged so that we must shoot to the southeast, which means that the sun will be on your sights from early to late afternoon. It also means I'm not sure whether the poor results on my last target were due to sun-induced sighting errors, a poor RB - patch combination, or both In all likelihood I'll retest this, but I'm not sure I'll get to it before our range closes for deer season in mid-November. (It closes only for CF deer season, not for ML's, bowhunters, or turkey hunters. Go figure!)