tks hanshi - my 42" .40, with a .398" ball, I think it was, and .022" denim patch, lubed with LHV made 2,240fps, or thereabouts with 65.0gr. 3F GOEX. With 75gr. GOEX 2F, that speed was virtually identical as-was the accuracy. 48" twist, Goodeoin barrel.
I might have been using a .400" ball with .020" patch. with a nicely smoothed crown, I find the .400's load virtually the same as the smaller ball with thicker patch.
This is the crown on the .40. To the actual top of the lands, is amost 1/4" down into the bore- a very short cone. The balls and patch form/draw/swage together quite easily, with never tearing the patch. I can actually shove the patched ball into the muzzle, with hand pressue alone on the knob of my starter - the pure lead ball swages that easily with this shape.
Since this picture was made, I've shortened the barrel to 36" & put it on a 1/2 stock. I recrowned it, similar, but not quite as deeply coned - just 3/16" from, larger than groove diameter, out to the tops of the lands. It loads identically, if not a tich easier yet than the longer cone. As before, the barrel will still give me 1/2" groups at 50 yards, with this load.