My Hawken GRRW .54 Cal.

[Kurt]

Rick.

When you get ticking make sure that it's 100% cotton. Wally has some that I looked at that is a synthetic ticking and it will not compress like cotton.
Also when you wash cotton ticking it will shrink some and thicken up. you might try to iron a small piece maybe it will stretch out again a little. You want a thick tight patch for the very deep grooves your rifle has looking at your photo or you will blow past the patch cutting it like the cleaning patch you used. Those grooves look like they are .010" or .012" deep on your barrel.
Get a good short ball starter that fits the ball and you might have to palm the starter to get it moving down the barrel. Deforming the ball slightly wont make that much difference at the ranges your going to shoot that rifle. The ball will also get bumped in the hinder when the charge goes off like a cartridge rifle and expand some into the lands. I have some balls I picked up. If I find them I will post a picture. It's surprising just how much they knead like putty.
Don't worry to much about using a little force starting a round ball. It's a different game from slug guns compared to round ball. I see guys using a rubber mallet starting round balls and shoot very tight groups.