YOu're right, RB- ther is a pucker above the ball. No load I put down has a pucker in the groove. The material compresses and 'moves' across the bottom of the groove, up the other side, across the top of the land and down into the groove without any doubling or puckering. This stretching and compressing is probably why we prefer a ball only .005" under bore size, along with a patch that provides at least .005" compression per side, to the bottom of the groove. This combination has worked in ten's of guns - maybe over 100 we've tested it in. It is as close to a 'formula for success' as can be.
My .69 is the only annomoly so far it seems, with over 125gr. of powder. Up to that, the .006" under ball works fine with a .0225" patch. After 125gr. I have to up the ante` with the 12 oz. denim, that measures .025" with my mic, and .030" with calipers. That barrel has only .012" rifling, not the deeper, .016" to .025" rounded rifling used in some other barrels. Those might need even thicker patching.
If the patch is not completely reusable with identical accuracy, it did not hold up to it's task, as far as I'm concerned.
I am in total agreement with Taylor's post - obviously. This 'system' has worked in every gun we've tried it in for almost 40 years - it did take us a few years of much testing back in the early 70's to discover it.