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Before we start eating patches and re-crowning barrels, something that might have been overlooked is the patch material itself. Several years ago I made a trip to Kemmerer WY, I realized to late that I forgot my patch material. So I made a trip to the local Alco store looking for ticking. They had three different colors, red, green, and the normal blue. It all Mic-ed .018 so I bought some of each. My groups went to heck. All of it burned through just like your pictures. It was pure cotton ticking but for some reason it wouldn't work in any of my 30 or so muzzle loaders. I have since been buying ticking from Wal-Mart as bad as I hate to shop there. You might try some different ticking before jumping to other conclusions. Just a thought.
Bob
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