Gil,
I have had excellent results with Pilkington's formula. I now mix my own rust blue solution based on Dr. Gaddy's formula as given in the Double Gun Journal. The final result is identical to Pilkington's. I live in dry Arizona and have to let the barrels rust for at least 8-10 hours. I even have a humidity chamber that is heated to about 90 degrees. When I lived in damp Portland, Oregon, the rusting time was somewhat less.
I would like to know what you do to get the barrels to rust so quickly.