Eric....Why are you convinced you need to pound balls down the barrel to get better accuracy? Sometimes less is better.
You didn't mention what distance you were shooting at. If you got a good group using .440 balls why did you change?
Have you checked your patches to see if they are holding up. Have you tried using a thinner patch with less or more powder?
I've tried teflon and didn't like it. For years I shot the same .45 Douglas barrel that you have using 65 grs. 3F by volume, .445 RB, .018 cotton patch, using spit for a lube and got great results.
The best shooting gun I own today is .58 cal. I can thumb press the ball into the barrel, no short starter. I load out of my shooting bag.
For years I thought the only way to go was with a tight patch ball combination. I have since changed my mind. I compete with guys who use drop tubes, teflon patches, oversized balls and see no difference between what they do and what I do. My philosophy is "if it aint broke don't fix it."
Centershot