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You’ve established that a small variation can make a difference at long range but you haven’t established that a grain or more of powder can/does get stuck in the barrel. I contend that even if it did the wad would push it all down.
I’d like to see some actual data. Maybe shoot the rifle and swab as usual. Then pull the bp and pour a weighed load down the barrel. Catch it at the breech and weigh again to see if you lost any to the grooves. Then do that 10 more times. Or use a borescope to look.
Then IF you identify stuck powder, then do that same test again and push a wad through the barrel each time to see if it is pushing any stuck powder on through.
I’d like to see some actual data. Maybe shoot the rifle and swab as usual. Then pull the bp and pour a weighed load down the barrel. Catch it at the breech and weigh again to see if you lost any to the grooves. Then do that 10 more times. Or use a borescope to look.
Then IF you identify stuck powder, then do that same test again and push a wad through the barrel each time to see if it is pushing any stuck powder on through.