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Doc,
I have never made my own wads; so I can't offer you any first-hand comments.
I found it interesting that you soaked the felt in lube prior to stamping the wads. On other threads, I seem to remember that most people didn't do the soaking until after the wads were stamped. So long as the felt was thoroughly saturated, I can't imagine that there would be a performance difference. Perhaps, one method is easier (or less messy) than the other. Have you tried stamping out the wads prior to soaking?
Regarding wad size: The pre-lubed wads that I use from Cabela's are actually marginally larger in diameter than the cylinder openings. When they are pushed into the cylinder, the wad is compressed slightly which results in a tight, positive seal between the cylinder wall and the wad. Whether this makes a difference or not is unknown; since we don't know what the diameter of your smaller wad becomes under compression.
I only purchased the pre-cut wads because it was easier for a newby. Ultimately, I will try making my own wads. Keep us posted on your results.
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napp
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