I think that for rifles, either German or American, the general rule was smaller balls, thicker patches. This, of course, gives you more leeway in the choice of patching material, but the thicker patching would be able to cram tightly into the deep grooves. Think about it. They couldn't go to the fabric store with a micrometer and measure their pillow ticking, looking for exactly .018" thick fabric. Smaller balls and thicker patches means you can use more varying thickness of fabric (or leather), and even if one was looser than the other, it would at least still fill the grooves and be usable. With the thick patches, I doubt that "stripping the grooves" was a problem. I would bet that these deep grooves and thick patches are the key to accuracy with faster twists.
Your 1 in 35" and 1 in 40" guns show that not all the rifle twists were the fast 1 in 24". That's similar to my two guns, which are in the 32-36" range.... I'll have to measure them again, but my memory, such as it is, tells me they were about that.