I used to post a link on websites for those that wanted to know how to get the best accuracy out of their Rile-Muskets.
Tony passed away a few years ago, but he was a "dyed in the wool" black powder shooter. His wife made the comment one time that they lived on a rifle range, their house just happened to be on Ton y's range.
Unfortunately, I think the N-SSA has now taken down Tony's article. I can no longer pull it up.
The essence of Tony's advice was to [In my words]:
1. Weigh all of your cast Minie Balls and separate them into Lots of Plus or Minus 1/2 Grains. The "Light" balls go back into the casting pot as they have hidden air pockets. Size your Minie Balls.
2. Load up 5 cartridges each with the same powder charge, i.e., 5 cartridges with 40 Grains FFFg, 5 cartridges with 42 Grains of FFFg, so on and so forth up to 60 Grains of FFFg.
Bench all the loads at 100 Yards. You will find one particular load that gives you the best group. Say, for example, your rifle-musket gives you a good tight group using 46 Grains. Then Load up 5 cartridges with 45 Grains and and 5 cartridges with 47 Grains and shoot them off the bench. Sooner or later, you will find the "ideal charge" for your rifle-musket...the one that delivers the tightest groups.
IF you change your brand of Percussion Caps or start using a different Lot of black powder, then you have to go through the entire process again to get the best groups.