some of the more accurate muzzle loaders

Grumpy

The Grumpy Grease Monkey mechanical engineer.
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some of the more accurate muzzle loaders are the 58 caliber-69 caliber rifled muskets and heavier octagon rifled barrel hawken clones
keep in mind the rifle twist rate must match the projectiles used.
almost all muzzle loaders have twist rates that easily stabilize a patched round ball,
purely from a physics standpoint, larger bore diameters result in heavier mass in projectiles and this tends to help accuracy IF the correct projectile is matched to a compatible twist rate.
by the time of the mid 1800s many rifled muskets designed to use mini balls would with the correct ammo hit a man size target very regularly out past 600 yards in a skilled shooter's hands, army ordnance and the better civilian gunsmiths went to great lengths, to do the research and in many cases the rifles, if properly maintained and loaded, were potentially far more accurate than the people using them.
keep in mind the powder charge and bullet diameter and lube used, must match the application to get great accuracy
over charges flare the mini ball base excessively, resulting in poor accuracy .
the larger bore muskets seem to prefer 2f powder but 3f can be used.




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The US Ordnance Manual of 1862 lists 70 grains powder for the 1842 with Expanding Ball, and 110 grains with Round Ball.
typically a 58 hawken clone with a typical 1 in 48 twist prefers a 60 grain charge with a mini ball and about 90 grains under a patched round ball load.
 
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