G'day from Australia, great site you probably have this info posted but is there a size chart for breech plug vs bore.
Regards.
Kiwi.
I dont know of any such chart, but you can figure it out by looking at Tap Drill Charts.
Take a 5/8-18 breech plug for example. The recommended tap drill size is 37/64 fractional or 0.5781 decimal. The largest practical bore size to give a shoulder for the breech plug to butt against is .54 caliber or 0.540. If the bore is rifled with 0.012 grooves, the diameter across the grooves would be 0.564 giving you only (0.578 0.564)/2 = 0.007 of shoulder in the grooves. Basically, you would have some shoulder at the lands and practically no shoulder at the grooves.
The same exercise for 3/4-16 plug would yield a largest practical bore size of .62 caliber. There would be a shoulder at the lands, but only (0.6875 0.644)/2 = 0.022 of shoulder in the grooves.
Doing the same for 7/8-14 plug would yield a largest practical bore size of .775" caliber like on a Brown Bess. You would have less than 0.007 shoulder in the grooves.