The second Squirrel Rifle Match at Hefley Rendezvous, Taylor and I used Peter's .40 (again) that Taylor built for him many years prior. Our accuracy was dismal to say the least - we BOTH shoot better than what was showing on the board - same the previous year - same rifle, same poor shooting. The vent on Peter's .40 had enlarged to the point that as I watched Taylor shove the snug patched ball down the bore, there was a spray of 3F whooshing out the vent. Hey- that's why some go pop and others crack! - yeah- we're slow. Merely closing the frizzen during seating, ended up with a full pan of powder - self - priming - too much prime too. We then plugged the vent while shoving the patched ball down and accuracy returned - too little, too late.
Vent size can make a big difference when the powder can be blown out the vent - some this shot, more next, etc. The vent size might have been around .085" at that time.