I understand.
But that's not going to keep me from trying LOL!
Okay, so I just got back from the Home Depot with a 1/2" dowel rod. I cut it down to manageable size and sanded one end into a half sphere shape.
I rolled up a new cartridge with the .509" ball, making sure to keep the paper and string tight and especially to have the string tight around the neck of the cartridge. I think the new former is working far better than the close pin I was using. The finished cartridge looked much nicer with fewer wrinkles.
I didn't put powder in, and instead tore the paper were it would be if loading, and put the package down the bore. To compare, I also removed the powder from one of my older .520" cartridges for comparison.
The .509 cartridge slid right down the bore easily, making slight contact with the sides of the bore. The .520" cartridge was a much firmer fit, actually had to press down hard with my thumb. I noticed some inconsistency with the .520" cartridges when loading at the range, that got worse with each shot so I am thinking my paper and string weren't tight enough around the ball and that coupled with the fouling is what caused the ball to get stuck but a smaller ball might well still be needed.
I will try and roll another, tight cartridge with a .520" ball and see if it is still easy to load. If not, I think I will make a batch of .509" cartridges and go test them at the range for accuracy and ease of loading.
Hopefully it goes better than last time! If not, I have a "super pistol rod" coming from Dixie Gun Works that should make removing a stuck ball much easier.
PS: I am wondering if I should downgrade my charge by about 20%, to 44 grains, to see if that cuts down on fouling residue. Does anyone think that will help?