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There are several problems in what you're trying to do.
Your beginning info was obviously incorrect.
Working up a load for the BP Sharps replicas doesn't come easy, and it's not a quick process.
An accurate load can easily take weeks to find. Also, 30 or 50 yards is not a good indicator. The people who make the Ballard rifles told me a few years back that they don't consider 100 yards a valid distance for accuracy testing in their rifles, because the big bullet hasn't "gone to sleep yet" & hasn't truly stabilized.
DO NOT TRY TO LOAD BY POURING POWDER DOWN THE BORE INTO A PRIMED CASE & THEN SEATING THE BULLET!!!!!!!
Are you using .45-110 brass? Sounds more like you're using .45-70 brass.
Your BP charge is "measured" by volume, not weight, right?
Denis
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