Machine the bore to 1.015", that way you can use a standard ball mill to make a mould, or use any standard 1" projectile with a lubed patch.
A 1" copper water pipe end-cap makes a nice powder measure, about 250 grain of BP, drill the touch-hole 1/8".
This guy make reasonable priced cannon moulds
w ww.jt-bullet-moulds.co.uk/
Here is a pic of the ball mould I made for my 1" bore cannon.
http://img.photobucket.com/albums/v337/alflipo/Picture537.jpg
A 1" copper water pipe end-cap makes a nice powder measure, about 250 grain of BP, drill the touch-hole 1/8".
This guy make reasonable priced cannon moulds
w ww.jt-bullet-moulds.co.uk/
Here is a pic of the ball mould I made for my 1" bore cannon.
http://img.photobucket.com/albums/v337/alflipo/Picture537.jpg