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In preparation for my upcoming pronghorn hunt I have been practicing diligently with my flintlock rifle. I also want to bring a back-up rifle. I had one in mind but after a few sessions with different loads it is not sighted-in and ready. Then I thought I might take my son's rifle. When he shoots it he gets bullseyes. When I shoot it I get the same size groups but not on the bullseye. It's his gun so I am not going to change sight settings. So the simple choice is to take my primary percussion rifle that has been reliable for quite some time.

This percussion rifle has shown a strong preference for 100-grains of powder. The sights have always been way to the right, physically on the rifle. You can see the rear sight is drifted way right. It is cursed with these quirks. Nonetheless, it groups excellent and it shoots right on the money at 100-yards. That is, until yesterday!

I shoot a 3-shot group at 100-yards with the old load of 100-grains, .018 patch and .530 ball, CCI-M cap. Huh, the group is 6-inches high and 6-inches left. Bring it in to 50-yards and results are similar. Move sights and doesn't move impact nearly enough. Groups are much bigger than ever before. How did this happen?

Back to the range today. Start with 100-grains and try a different patch lube. Groups get even bigger. Go back to old patch and group is large but smaller than lubed patches. Move sight (front sight and back sight). Group moves but is large and inconsistent. Clean whole rifle. Bright idea, go look at patches. Patches show tearing around ball imprint. Reduce powder charge. Group improves so I adjust sights. Group moves accordingly. Patches are better but 2/5 are still tearing. Reduce charge to 80-grains. Group shrinks again. Move sights again accordingly. Clean rifle entirely. First shot at 100-yards, bullseye. No swabbing, second shot 1-inch to left. No swabbing, third shot touches first shot. Come back to 50-yards. 3-shots the same way produce a clover-leaf right on top of the 3" bullseye. Still not convinced I clean the whole rifle again. First shot at 100-yards, bullseye. No swabbing, second shot makes figure 8 out of first hole. Back to 50-yards, 12 o'clock on bull. I checked sights to make sure no movement, cleaned entirely and put the rifle away. Here's the blessing: the sights are now physically centered on the rifle and the rifle shoots the exact same load as my other two .54 caliber rifles.

I don't write this seeking advice or explanation, it is what it is. How did this happen? I have no idea. One possibility is that this barrel came to me a little rusty with light pitting. Every cleaning would yield some orange colored patches. Recently, the orange stopped coming out. No more orange. After 100 or so shots and subsequent cleaning the orange is gone. Maybe a total coincidence that the point-of-impact moved about the same time the orange disappeared. I document this for the person that is frustrated with poor groups, experiencing a change in point-of-impact or can't seem to get sighted-in. Something changed. I can't pinpoint it. However, going back to the load experimentation regiment led to a good accurate load - even though it is different than what previously worked. If you are seeing sudden changes and your components and technique are the same as always it could be something unforeseen and may need a new load to overcome it.

Before leaving the range I pulled out the flintlock I plan on using as my primary rifle on this hunt. At 100-yards off sticks the first clean barrel shot was a bullseye and the second fouled barrel shot was an inch off. Thank God for that!
 
You have probably shot your percussion rifle enough to have opened the flash hole in the nipple such that you get inconsistent pressure in the firing chamber. Change the nipple or accept the fact that sometimes bad things happen.
 
You have probably shot your percussion rifle enough to have opened the flash hole in the nipple such that you get inconsistent pressure in the firing chamber. Change the nipple or accept the fact that sometimes bad things happen.
Was thinking the same thing as I read the OP. When shooting heavier conicals (4-500 grain) in my fast twist 45 caliber guns over moderate charges of fff Swiss (80-110 grains) have had point of impact shift 3 or 4 inches at 300 yards with 40 or less shots fired with stainless nipples, both Hotshot and also what I’ll call generic. Measure orifice or base hole in the nipples with precision gauge pins and have seen over .010” diameter change occur after a few sessions with the heavier conicals and loads. Found the Treso Ampco nipples to be a lot tougher and lasting at least three to four times longer with same loads. They start at .028” diameter and I set them aside when they reach .035”. Seems to have, at least in my experience, help eliminate the shifting of the point of impact.

Thought about the platinum lined nipples, but at $60 to $70 a piece, and the way I drop and loose nipples, I’ll stick with the $5 Treso Ampco.
 
good idea about the nipple! I viewed this under a magnifying glass. It appears round with smooth edges. Comparing it to others, it seems the same sized hole. It is awful small so it is hard to judge visually. I would think an worn nipple channel or hole would cause erratic pressure across all loads with no way to keep consistency. Could be, but does not seem to be the case here. I have many replacement nipples and will certainly try a fresh one on the next range trip. Thanks for that suggestion!
 
You said the rear sight is way too the right....

Is the front sight centered?

I once had the same issue with a rifle.... one sight going one way the other the opposite.

Is the front sight left of center?
 
Have you shot it since you moved the sights?

If you were only off by 6” at 100 yards already, it doesn’t take much of a move too get that 6”.

Especially if you move both sights.

My gun acted the same way once , until I realized what was going on with my sight sitting on opposite sides of the barrel..

Once things were centered the gun was back where it once was.

It shoots a lot better than I do.....
 
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The sights are centered on the barrel. The bore seems centered with good crown. It is sighted-in just right with tight groups. Just a totally different load and sight setting. Was previously sighted-in and always proved right on the money for nearly 3-years. Suddenly same old load shoots high/left - a lot, and loss of grouping. New load made a tight group, moved the sight to adjust point of impact and all is good again.
 
The idea of taking a back up rifle seems awkward to me. These muzzle guns are one-shooters and we learn to live with that. In fact, it is sort of the main idea for using them. Leave the second rifle at home and focus on your one shot placement. Just my tuppence. BTW, nipples are cheap disposable items. If you even suspect one is burning out, replace it.
 
My back-up rifle is the muzzleloader I spoke about. I have no doubt my flintlock will perform and one shot will end the hunt. However, what if.... There are numerous potential scenarios that would render one rifle out of commission. Nobody else on this hunt has a rifle I would be interested in borrowing. Worst case would probably be a dropped rifle that breaks a stock, sight or hammer. Rain-soaked might be tough to remedy out in the middle-of-nowhere, although I will take measure to prevent that. The back-up is not to use or even carry in the field. It is to replace a disaster. If disaster struck both rifles, I'll come home.....
 
My back-up rifle is the muzzleloader I spoke about. I have no doubt my flintlock will perform and one shot will end the hunt. However, what if.... There are numerous potential scenarios that would render one rifle out of commission. Nobody else on this hunt has a rifle I would be interested in borrowing. Worst case would probably be a dropped rifle that breaks a stock, sight or hammer. Rain-soaked might be tough to remedy out in the middle-of-nowhere, although I will take measure to prevent that. The back-up is not to use or even carry in the field. It is to replace a disaster. If disaster struck both rifles, I'll come home.....
A backup rifle is always a great idea. ..especially when far from home!
 
The idea of taking a back up rifle seems awkward to me. These muzzle guns are one-shooters and we learn to live with that. In fact, it is sort of the main idea for using them. Leave the second rifle at home and focus on your one shot placement. Just my tuppence. BTW, nipples are cheap disposable items. If you even suspect one is burning out, replace it.
Unless hunting in my backyard, I take at least one backup, and at times two backups. Drive 1800 miles round trip with one rifle ‘to focus on shot placement’? Or fly to a destination with one rifle because taking a backup ‘seems awkward’? The guys that show at camp totally unprepared usually aren’t shown much mercy, let alone invited back, kids and new hunters being the exception.
 
Unless hunting in my backyard, I take at least one backup, and at times two backups. Drive 1800 miles round trip with one rifle ‘to focus on shot placement’? Or fly to a destination with one rifle because taking a backup ‘seems awkward’? The guys that show at camp totally unprepared usually aren’t shown much mercy, let alone invited back, kids and new hunters being the exception.

Taking a spare rifle on the trip is a good idea. But he said hunt. Carrying a second rifle into the field is not what this sport is all about and, definitely, is awkward.
 
When I first responded, I was thinking of the quickest and easiest as well as most likely factor that could effect accuracy. One other thing to think of is just how much residual fouling has built up in the grooves. While waiting to go to the range, I would get out the brake cleaner or lead remover and scrub out the barrel. I don't think the barrel has been misused, but a bit more scrubbing based on the sudden change of accuracy in your rifle would be in order.
 
Took OP statement
preparation for my upcoming pronghorn hunt I have been practicing diligently with my flintlock rifle. I also want to bring a back-up rifle
to mean he wanted to bring backup rifle on a hunting trip. My mistake.
Taking a spare rifle on the trip is a good idea. But he said hunt. Carrying a second rifle into the field is not what this sport is all about and, definitely, is awkward.
Missed that he meant a hunt and carrying a second rifle. Thanks for clarifying.
 
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