NB.nagantsniper
CGN frequent flyer
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Pure lead balls aren't used because the obturate the gap between barrel and ball - that is the purpose of the patch. The pure lead is soft enough to grip the patch and somewhat of the rifling lands so the ball follows the spin of the rifling.
But would a hard cast ball grip the patch enough? The reason I'm asking is that I've never used anything but pure lead in my smokepoles. I reserve harder alloys for bullet casting. It's just that I have had at least 5 CVA's in 45 - 2 Kentucky's, a squirrel rifle, a Kentucky pistol, and another pistol that I can't remember the model, and all were accurate enough to make head shots on grouse at 25 yds. with no issues whatsoever. The only time accuracy dropped off on any of them is when I tried heavy powder loads. My wife also has a CVA in-line that is super accurate, so I would have to suspect the load rather than the gun.
In over 50 years of shooting caplock muzzle loaders I have found that the load with just enough powder to get the ball to the target will be the most accurate. That is with a soft (pure) lead round ball and a lightly greased patch that is a "snug" fit in the bore. Recovered balls from these light loads will sometimes show the thread pattern of the patch material where the patch rides on the rifling. Recovered patches will tell you a great deal. The patch should be intact. no holes burnt (gas blowby?) and not cut by the rifling. If your patch material fails as you work up a load groups will get bigger.
The next thing that will increase group size is the diameter of the hole in the nipple - a new nipple can drop group sizes with heavier loads. Combine a worn nipple with a weak hammers spring and you will get erratic ignition and larger group sizes with heavier loads. A very weak hammer spring and a worn nipple will sometimes leave the hammer on half #### after you fire. I have dealt with a couple of spanish guns that had this problem. Proper tempering of the hammer spring and a new nipple brought group size down considerably.
just tempering a spring will do nothing as tempering draws out hardness in turn making the spring weaker. you would have to anneal(maybe even normalize) the spring then re harden said spring and then temper the temper is something you have to experiment with too hard and you risk breaking the spring too soft and you have a weak spring or one that just collapses altogether