OK. . .reboot of the construction technique started up on the previous page. Also having difficulties uploading some of the photos of rolling the paper patch - hopefully can splice them in later. Suffice to say for the moment that we went back to the template from original blueprint's design and found it works quite well with the Accurate Molds bullet after all:
Pop constructed the patch forming mandrel to provide a handle as the patch is rolled. Hopefully I can get the pics to behave, but the trick is to put an index mark right at the ogive on the bullet used for the mandrel and start one corner there. The front of the patch will come off line a little when you get toward the middle of it, but it will even up as you finish the roll and glue down the back edge.
Insert bullet into back of cone and follow it with the powder case. We still need to tinker with dimensions somewhere, as the powder case takes CONSIDERABLE finagling get shoved fully in.
Start with about 10" of dental floss and tie the first half of a square knot on one side of the cartridge case, just behind where the top wad sits. Cinch this down REALLY. . .FREAKING. . .TIGHT! Then take the ends of your floss around to the opposite side of the case and tie a complete square knot - again, REALLY. . .FREAKING. . .TIGHT!
For the moment, we smeared the paper patches and the tail end with a blob of SPG lube we had handy. These are snug going into a clean chamber, but they do go. Some dimensional tweaking may be in order, but we have seen the light. Range reports to follow!