If you are shooting PPB's with smokeless most people have good luck with groove diameter (wrapped) but they don't work so well with BP. The bullets you are trying to use are too big for BP. I don't shoot smokeless with PPB's but this is how I load with BP

My bullets for 45 caliber are 0.440 as cast, max 0.450 wrapped. Helps to rub a little lube on the paper before loading, assists getting the cartridge chambered.

Drop the charge into the case thru a 30"+ tube
Insert a card wad (milk carton)
Compress the charge as required
insert a lube cookie of 0.100 - 0.150" on top of the card
second card
disc of wax paper (helps insure the top card wad does not stick to the base of the bullet and falls off immediately out of the muzzle to ensure consistent bullet flight)
seat bullet about 0.150-0.200" into the case

Oh, almost forgot. Taper crimping is important, you will probably cut the paper if you use a roll crimp. If you don't crimp the bullets are easy to dislodge when handling the cartridges.

Ranch13 wrote on Oct 7^th, 2023 at 9:44pm:


That's been a problem with my first loads. They were very mild with 105 grs. of 1 1/2fg and filler, but very poor accuracy. Thus my reason to switch to full loads of to see how it does for accuracy.

You might just for kicks and grins try seating a bullet in an empty case. Then measure how far into the case the bottom of that bullet. Put enough powder in to come to the bottom of a .060 wad and then add enough to compress about .10. Recoil is definitely going to go up but you might find some accuracy. And you might also try some of the thick cork or felt wads to use as a filler. I'm pretty sure that using loose filler doesn't give an even push to the base of the bullet causing accuracy problems.

With my 50-90 high wall I weigh Swiss 1fg and use cork wads to fill in the gap between the powder, which I compress .1”, to the base of the 525 gr bullet. 

Fwiw,
Steve

steveu wrote on Oct 8^th, 2023 at 4:41pm:


Are you punching your own cork, or find cork somewhere online that is the right diameter?

You might also want to look at Shiloh rifle forum,
Kenny wasserberger shoots a lot of 45-110
And talks a lot about wad stacks of different materials 
Shooting at the wasserberger mile match. He is very knowledgeable 
On bigger Bpcr cartridge rifles. I belive he has a book out on the
Subject also. The biggest i shoot is 45-90 so I fill
Case with 1.5 Swiss to bottom of bullet with 1 .060 wad.

Marlinguy, have you done a chamber cast on this rifle? 
I ask because depending on who built the gun may have used one of the large diameter and long throats. If that's the case then you may have to go with a fairly large diameter bullet for the caliber to get anything resembling decent accuracy.