Ronward,
OK, now I think I have a better understanding of what you are talking about.
BP cartridge guns have higher pressures due to the fact there is no "pressure release" point as in the touchhole on a flinter or even a nipple on a percussion gun. Gas pressure escapes through the touch hole in a flinter and if everything else is equal, a flinter will have less gas pressure since the gas can more easily escape through the touch hole. Too high of pressure in a percussion gun will cause the pressure coming from the hole in the nipple to throw the hammer back to and stop in half cock. When loads are not that quite high of pressure, they can/will still cause the hammer to rise in a heavy load and then settle back down on the nipple from the foce of the mainspring acting on it- all before you would ever notice it becaue it happens so fast. Also, in BP cartridge rifles, the bullet is larger than the bore and forcing that ball into the rifling causes higher pressures as well.
Gas pressure in a muzzleloader comes from the type of ignition system (as explained above) the quality of powder, the type of powder, the size of the powder grains, the amount of powder, the shape of the projectile, the size of the projectile, the weight of the projectile, the thickness and strength of the patching material, amount the powder is compacted, the size of the bore, and the twist of the rifling as a faster twist resists the ball going down the bore more than a slower twist and will have higher pressure from that alone, hot or cold temperatures also affect gas pressure from BP in loaded rifle barrels. There are most likely other things I am not thinking about right off the top of my head as well.
We have to be careful when we talk about the types and quality of powders in the 18th century as gun powder was not as scientifically tested as it was even during the middle of the 19th century, let alone today. We have no circa 1750 and circa 1830 cans of brand new black powder to test today. However, it is generally accepted from empirical evidence that the quality of powder was much better circa 1830 than it had been in 1750, generally speaking. Due to that alone, the same charge of the same size powder would give higher pressures in the circa 1830 powder than the circa 1750 powder.
When you talk about using the same charge of 70-80 grain charge of BP between a .4 and .5 bore round ball gun and I assume with similar patching material, rate of twist, etc., etc. The pressure should be at least measurably greater in the .5 rifle than the .4 rifle. This because there is more resistance going on in the .5 barrel with the heavier bullet. The size of the "expansion chamber" between the two bore sizes does come in as a factor, though, we are assuming both balls are seated correctly on the powder before firing and the difference is in the size of the bore the gas has to fill as the ball travels down the bore. However, the resistance of a 177 grain .490 size pure lead round ball is much greater than an 89 grain .390 size pure lead round ball and without doing all the calculations, that should mean higher pressure in the .5 rifle even with the larger bore size. The .5 ball is almost twice the weight of the .4 ball and that is a significant amount or resistance difference.
What many people don't understand is that much of the force of the gas pressure is used up after the powder is burned and getting the ball to start from a velocity of zero up to it's main speed. As the ball goes down the bore, it does slightly increase in speed even though there is not as much gas pressure as there was back at the breech. In other words once you get the ball moving, it doesn't take as much force to slightly increase the speed of the bullet as it did to get the bullet moving. This is true in both BP and cartridge guns, even though there has been far more testing with cartridge guns in this area.
Now, there will be a higher VELOCITY in the .4 rifle ball with the same powder charge because you don't have as great of resistance with the smaller .4 ball because it weighs so much less. Even with less gas pressure, you are slinging a much smaller ball with about the same amount of force when you use the same powder charges.
Gas pressure and velocity are not the same thing and I think you are mixing the two together?
Gus