Did you wash the fabric first? This will get the sizing out of it and make it softer plus easier to load and work with.
The current ticking I'm using in all my rifles measured .030" new in the store, using calipers. Washed once then tumbled dry, it measures .0215 with the same calipers, and .018" with my 1" micrometer.
In a barrel with wide lands and narrow grooves, like my .32 barrel pictured above, a .311" ball works perfectly with it and easy loading with a 5/16" hickory rod.
In wide groove, narrow landed .40 barrel, also pictured above, I can shoot a .400" ball with the same patch, loading just like Taylor did in his video.
The other barrels along with the .40, use .395", .684" and .445" balls with the same patch. The balls are only .005" to .006" smaller than the bore, yet the seemingly heavy patch is easily loaded without having to use a range rod. None of my barrels have deep rifling which allows even heavier patches yet.