TKO,.... I think you'll find yore "patch-ball" combination a liddle "loose" and, accuracy somewhat lacking. I'd suggest try'n the thicker patchs, with the .490 balls, fact is, you may even find the .495 with thicker patchs to be the most accurate in yore individual rifle (hardly ever, do 2 rifles "like" the exact same combinations of, ball-size, patch thickness, lube, powder-charge, and etc.).
Also check the "integrity" of yore fired patchs while at the shoot'n range. If yore recovered "fired patchs" are charred with holes in'em (or, better described as "blown patchs") the "combination" isn't right. Recovered patchs should look to be in perfect condition with only a liddle "discoloration"!
I've also heard reports of the TC precut patchs not be'n of uniform thickness, and may not be exactly the thickness labled on the package. Most dedicated "roundball shooters" find ther patch material in fabric stores (some of us even take our "calipers" along when shop'n for pillow-tick'n).
Avoid "blown patchs", and find the powder charge thet gives you the most accuracy (you do have an "adjustable powder-measure", don't you?), and you'll be shoot'n "bullseyes" in no time.
I'd start out with a powder-charge of 50 grs. for starters, and increase the charge at 5 grn. intrevals to see what yore groups do, they should shrink slightly then open back up as you reach the point thet you need to start back the other way to finally settle on the "powder charge" she likes the best.
If you ever do buy pillow tick'n from a fabric store, be sure'n wash it a couple'a times before use'n it for "patch'n",.... wash'n it removes the "sizeing" (starch) in the material.
All this be'n said,.... traditional muzzleload'n rifles are "simple creatures" and, none of it is "rocket-science".
Take care, and have fun!!