Two or three things about heavy bullets in muzzleloaders and gas checks.
Heavy bullets. I've had many people ask me how much powder do I use for my heavy bullets, thinking that like sabots, we are using 120 grains or so. In actuality, I use 70 or 80 grains max for all of my shooting with a heavy bullet. Muskets were using duplex loads of 70 grains at the most as far as I know and using 500 grain minies.. It only takes getting them off the powder, the bullet will do the rest.
It's more important to find an accurate load rather than how much your shoulder will handle. The reason I don't use more powder is that I discovered completely by accident that a deer shot with 70 grains is just as dead as one shot with 90, and in some cases, 70 was most accurate... that to me is the key.
You touched on another thing, twist. Big bullets that are also long bullets, require a fast twist.
http://kwk.us/twist.html is an interesting site I found surfing around over the weekend to help with this and for example with my .451 caliber volunteer that shoots a bullet at roughly 1200 fps with a 1.2" - 1.3" bullet max, you see my 1-20" works at low velocities, and that is key, can you stabilize the bullet. I can get bullets up to 1400 to 1450 with a little more powder, but I'm hunting close range so for me its "why?".
Gas checks. I love gas checks in a muzzleloader bullet. I had one experience where I was at the range with my favorite bullet and shot a 90 grain load for my first shot with a 470 grain bullet and hit the black. My second bullet I don't remember even hit the paper. I had forgotten to bring my walters wads and had no reasonable way to make wads so in frustration, shot up my supply of lead bullets... and out of 20 ... hit the black twice...
While packing up, I found a box of some Mose copper cruisers, a 470 or so grain gas check bullet. Just to spite myself, I loaded one of them (they load slightly harder than lead) and took a shot at a fresh target... and hit the black.... and no... wasn't using black construction paper as my detractors like to charge from time to time ...
This revelation was a surprise and my second shot was also in the black... as was the third forth and 5th. Was it the gas check cleaned up the leading? That would be my assertion.
Back to the leading in the first place. That was a consternation to me. I have never had that situation develop prior, nor since shooting bare based bullets... I don't usually shoot 90 grains, but that was a particular effort to compare an experimental load with a Pyrodex P load and maybe I had some debris in the bore that started the leading on the first shot.. don't know... but I usually use powder, walters wad, bullet.
Gas checks... I prefer them now to a basic bullet but in the manner that I'm making bullets, is a more tenuous process if you are using a lubrizer in my case... but that could be cuz I'm self taught.... and that isn't always the best course of construction...
I'm not dissing bareassed bullets. I shoot them as much as my gas checks and due in large part to superstition, shoot them more often for hunting than the gas checks, but they are fun to make, great to shoot (and this too has a lot to do with the guys who designed the gas checks I shoot) and I'm convinced anyway, eliminate leading.
My story... one of many... and I'm trying to remember if I should stick to it...
Much aloha...