Brown Bear, you obviously did NOT read my first post in this thread. I never said anything about ceasing to study or about NOT correcting for very small and very large calibers.
I said Davenport was on the right track. That the formula skews off for the extremes in caliber. A load for a Brown Bess calculated under the formula would be unsafe. Davenport recognizes that powder burns at a particular constant rate for bore diameter and length and arrives at a result by calculating the volumne of bore times a powder constant. For very small and large calibers, I suspect that the powder burns at a slightly different rate. For instance putting 50 grains of powder into a 28 cal bore, would (again I suspect,) burn more like a fuse over the few inches of bore such a charge would occupy. Likewise in a large bore, a higher charge of powder takes up less inches of bore space. A larger portion of the powder can be consumed in the first inch of a 58 cal bore, than for instance in a 28 cal. Davenport relies solely on a burn rate constant x cubic inch of bore. I personally feel there is another variable that needs to be incorporated to account for the differences at extremes of bore size. The same was true for the Greenhill formula for determining a stable bullet length for a bore with a known twist. Certain erratic features of Greenhill's formula were corrected by factoring in velocities.
Some folks shoot a rifle and are happy. Most muzzleloader enthusiasts realize that there is a difference between round ball rifling and conical bullet rifling. very few make any attempt to understand the differences in rifling and twist beyond that. Depth and width and shape of grooves, the width of grooves as compared to lands, and what configuration of rifling is more accurate for rest shooting . If you have deep square grooves is one type of patching better than the standard commercial cotton drill sold in the stores?, I suppose some would say it takes the fun out of shooting to study such mundane things. Personally, whatever it takes to shoot better groups is what makes shooting fun for me. I am trying to find a barrel maker to cut slow twist Alex Henry style rifling for a muzzleloader gun, but so far no takers.