Mr. Marcruger, you'd lose your big money big time betting that double ball loads would "print far, far away from a normal load'. Carole was a deer hunter but no longer had the hand strength to load her .50 Thompson Center. She asked me to build a .40 flintlock that she could shoot. She liked it and wanted to hunt deer with it, but the ball weight of about 90 grains is not legal in Utah, has to be at least 170 grains for deer. I could not find a suitable conical in .40 caliber then. A game warden friend, Chad, suggesting using a double ball load. Here is Carole's rifle I built with a 12 inch length of pull, 36 inch barrel. The eagles are copper and the silver is sterling.
She wanted four hearts (for her family) as a thumb inlay and I threw in a Monarch butterfly.
She was known as "Eagle Lady". Here a test target with Swiss 2F.
I tested double ball loads in my ,40 Jacob Wigle I built. I seated one patched ball and then ran another patched ball down on it. Never had any air compression problem. I found that the double ball load lost about 450 fps over the single ball load. This was not enough velocity for deer hunting, so I doubled the load to get up to hunting velocity.
The top left target is 70 grains of Goex 3F, velocity is 2201 fps with 36 fps spread. The target below it was shot with double patched balls and gave 1765 fps with a 9 fps spread and cut the group size in half.
The middle top target is 70 grains of Swiss 3F (same bulk measure, not weight) at 2361 fps/40 fps spread. The target below it is with the same powder and charge but double patched balls at 1863 fps/15 fps. The second pair went wild, the only time I had that happen, but the first pair went through the same hole and the third pair hit about an inch apart.
Top right target is with 70 grains (bulk measure) of Swiss 2F and went 2271 fps/41. Bottom right target is the same but with double patched balls and went 1784 fps/18 spread, and is about a third tighter.
Carole killed a mule deer buck with the 70 grains of Goex 3F double ball load, at about 70 yards.
This double ball loading was to meet a specific need, having a legal ball weight for deer hunting. We recognized the danger of shooting separated double ball loads. and Carole did not do it again. Carl had me build her a .50 fullstock flintlock to her fit, for their 50th wedding anniversary. I DO NOT RECOMMEND DOUBLE BALL LOADS AND ADVISE ANYONE CONSIDERING IT NOT TO DO IT. If you must, be very sure both balls are down. The double balls do not equal the weight of a conical, which are shown in Lyman's handbook with powder charges equal to the maximum shown with a single round ball. But if those balls separate in the bore- as shown by Taylor- the rifle can be ruined. George out here was doing the "cut the 2x4" in a race at a rendezvous, using double balls. He destroyed his rifle.