Your aversion to paper patching is holding you back from success. The rifle was made to shoot paper patched bullets. Do it!
Secondly, your bullet diameter is limited by your chamber neck dimension. I think you will find that a bullet of sufficient diameter to fill your bore or throat will result in a cartridge that will not fit in your chamber. If you make things too tight in the neck you are courting danger.
I am loading for my original Gibbs-Metford Farquharson MBL target rifle. .461 No. 1.
To begin, I used plug gauges to determine my chamber neck diameter and worked dimensions back from there. Specific to my rifle only, I found that a .485 plug goes freely in the chamber neck, whereas a .486 plug meets interference. Neck thickness of my brass is 0.011, so the brass takes up no less than .022 of the neck diameter. Thus, the absolute largest diameter bullet I can load would be .463, but thats taking it to the limit. You need some clearance.
My research told me that the Gibbs No. 1 round was loaded with a lead bullet of .451 to .452 diameter with a paper patch bringing it out to about .459. The soft lead bullet would conform to bore dimensions when launched by the sudden impact of black powder.
Bringing it full-circle, I am loading a swaged bullet from BACO - their excellent .451, 480 grain paper patch bullet. Using two wraps of 9# onion skin, my bullet finishes to .457 to .458. That gives 5 or 6 thousandths clearance in the neck, which you will need for bullet release and to work around fouling. My latest load is this bullet over 75.5 grains of OE2F, a CCI 250, topped with a beeswax foundation wad, Ό grease cookie, all with an OAL of 3.170. Your powder charge must be compressed to the exact depth to accommodate your wad column and bullet. The bullet will not do this compression. You must use a compression die, properly calibrated.
If you plan to shoot these antiques you must conform to loading practices in use when they were made. Modern components and practices often are not appropriate.
(You need to Login or Register to view media files and links) Good luck,
Curly