I think you have it right, about smoothbores not giving any Leeway for patch fabric to move or "stretch", compared to what happens in rifles.
My first shots with RB that were .600" diameter, in my .6265 bore were with very thin denim, that my brother gave me from some stash. Neither of us like the results. Clearly they were too thin, for that ball/bore combination, as shown by the dark wide, black ring, and streaks on the spent patches. I have thrown what I had left of that stuff away.
I bought some Mattress ticking, and its been washed. I need to iron it to make it easier to cut into strips, and then I can get back to testing. Its measuring close to .015" thick, right now, but I want to measure it again after its ironed.
I also was given a handful of .610" balls to try. We will see. I would much prefer to use a thick patch, and a smaller diameter ball, than a larger ball, and a thin patch.
I also tried using an OP wad, under both my RB, and shot loads, and saw an immediate, and substantial increase in velocity, using the 19 gauge, .125"thick, Vegetable Fiber wads. I am taking over 200 fps! In rifles, I have found using an OP wad will increase MV by 50-75 fps., but never as much as I found with this fowler. POI at 25 yds rose 8 inches, Too!
One of the reasons I am trying to find the correct patch/ball combination for this barrel is so I don't have to use an OP wad. Its not much of a hassle, compared to loading shot loads, but like most everyone else, I am searching for the simplest loading procedure that produces the best result. Since the air in front of my OP wad is pushed through the powder charge, and out the TH, putting the OP wad down is no big problem. Its just another step. If I can avoid it, I will. :thumbsup: