goodsteel:
If you use a donut wad under the undersize balls they should do okay. Or your cupped leather wads should also keep the ball centered.
Another option for the 0.675's is to use some paper to take up the slop (or cardboard as excess650 did). I just roll a piece to form a tube then insert that before the ball, or use cross paper strips over the mouth of the hull and push the ball in so they fold around the ball as it is seated into the shotcup. Works for me.
Did you recover any wads? They can tell a story too. I have often found blown gas seals, extruded top of cushion and/or shredded petals. When the wad is damaged accuracy usually suffers.
Sounds like you have a couple of good loads there though. The 0.675's and 0.685's should do best in shotcups. You might find different shotcup materials have an effect too. I have had poor results using Win AA Red wads. They are quite thick and soft. The harder Winchester white and yellow have worked better for me.
I had thought the 0.735 RB's would be the best for me, and they did well, but I did get a few fliers that opened groups up some. I recovered a few balls that showed an uneven band around the ball from bore contact so figured that was from rolling into the barrel from the forcing cone. The same loads shot very well from a rifled gun though.
Not sure how the ball would get spinning as it hit the forcing cone but I can't think of any other reason for the uneven bore fit unless a wad tilted as it drove the ball down the barrel. I loaded these over 1/2" hard card wads though so... ? Wad column is very important!
So far with balls and slugs I have had better results using shotcups so have continued along that path.
I need some range time and get some more shooting done though!
Longbow