Charlie.
I dont shoot jacketed bullets or smokless powder in my sharps or trap doors.You should slug the barrel and fit the bullet to it.
I cast my bullets .001-.002 smaler on the ogive or bore,and fit the groove.
take my Shiloh it mesures .400 bore.408 groove.my mould is cut .398-.408.
Like Krag man said the old trapdoors run a little large,I have found them at .462.With a .457 bullet in that barel you will get gas cuts even with a jacked bullet.
I would stay with black powder in those old rifles I think you will find they shoot better with it,and the rifle cleans better with it.I can get my powder rifles clean faster then I can smokless with jacketed bullets.
And yes the jacket should be larger then the bore.But regardless what is said at times,the smokless load will slug up a jacketed bullet some.
Lp.