Casey-
First off, hello and thanks for the relevant information.
As you probably know, a double rifle is made to handle a particular specific load of ammunition, and will when properly loaded and handled the double rifle will put the groups of both barrels on the Point Of Aim in parallel trajectories until the bullets hit the ground.
I'll also assume that you know that black powder bore rifles are pretty 'load tolerant' and will often perform well 'at regulation' with more latitude than the high-strung express rifles and cordite express rifles.
Given all that, I'll note I'm seeing a 51 grain difference in projectile diameter here, and also the bearing surface of the bullet will be greater than if it's simply pure lead ball of proper 'groove or just a couple thou more' diameter.
So, I wonder...
How long do these bullets end up being once they're formed?
Is this a modern made double rifle or something from the 19th century?
How well do your loads perform in your double rifle, are you achieving good accuracy?
What is the case length, the load, and the accuracy?
Do both barrels print to (essentially) the same group?
Does this load hit to the original sights of your rifle?
Do you know the velocity of the load that works best in your rifle?
Thanks a lot for the tip, and also thanks for sharing your experience.
--Tinker