Ken,
See my comment on the Moose shooting thread..
Bob and I after that escapade ordered a .480 round ball mold from Rapine.
I have shot a bunch of .480 round balls cast out of wheel weights using a thick pillow ticking (23 thou) patch. I have tried other patching materiel, but it seems to be too loose of a weave and I have blow-outs. I am using around 80 grains of FFg for a normal load.
I think, for deer hunting, I still prefer a soft lead .490 round ball though. The bigger the ball and the more mushrooming I can get, the better I like it. It all increases the blood channel.
I may be thinking all wrong, but I have come to the conclusion that a round ball kills the same way an arrow does... By cutting a blood channel.
Most modern rifles tend to kill with shock. (Have you ever looked at the hydraulic shock trail that a .22-250 makes in a gelatin block?) Well, it does the same thing to a ground squirrel... He explodes.....
A muzzleloader on the other hand, just punches a little round hole through a ground squirrel. Same thing happens to a deer... Therefore, I believe that the bigger I can get that hole, the more shock, blood loss and trauma the animal is going to instantly have.
Of course, you have to measure the penetration along with this.... I have known several folks who have shot animals and the ball never penetrated the hide of an animal. It was still in a hide pocket shoved down inside the body cavity of the animal...
I also shot and lost a nice buck by hitting a front shoulder bone which stopped a .45 round ball... Then again, I once shot a mule deer in the side and kicked up dirt behind him before he fell over dead...
I think one needs to think about all of these things before you make a decision concerning what round ball you are going to shoot.
Now, Paper Don't Care...... Neither do Beer Cans.....