Now! You are getting to the important first point in designing the proper combo for ball'bullet to the smoothbore!As to just how hard, or soft, an oversize ball/bullet should be in a smoothbore...is still open!
We know what Greeener, and the rest, said over a hundred years ago about a harden ball....Slip Fit!
Dixie has specialized for some years with hard cast heat treated slugs...period. We are not going to go to soft lead since it has been proven to us that it just does not perform what our
teat treated bullets do! This rules out much, for us much of what the hobbyist can play with in smoothbores. Since I refuse to deal with speculation, I just do not know what would be safe with oversize balls/bullets in smoothbores.....James