I believe the old timers loaded with a far looser patch/ball comb than we do today.
Absolutely, I'm sure they(for the most part) did. However, by the mid 1800's there were gun clubs around, in the West as well as the East, where
accuracy was of utmost importance and I am absolutely positive, tight loads are nothing new in that realm of shooters. There are accounts of exceptional
shots who put 5 balls on top of one-another at 50yards. I've not seen that level of accuracy occur with loose loads - maybe some day, though I wouldn't bet
on it.
If the barrel is smooth and not pocked by poor cleaning regimes, then loading tight loads with a thin rod is not all that difficult. However, if the load is loose
enough that fouling builds up, or the bore pocked by fake powders at some time in the past or through poor cleaning regimes, then indeed, a slim rod can be
difficult to load with.