I think I've got this problem whooped. Although there is still a visible raised edge or burr over much of the land edges, I think it's smooth enough it doesn't cut patches.
I shot a bunch of minute men 0.020 patches with 0.526 ball over the weekend in the gun, and the patches looked PERFECT. It's probably more of a testament to the patch quality. Man they are tightly woven.
With the 0.020 minute men, it measures with my calipers hard as I can squeeze them about 0.018 when new and unwashed. After a washing and drying, they're 0.020-0.021 and TOUGH.