Dan,
I had the same questions when I put my golf ball mortar together. Take a look at this post:
http://www.gboreloaded.com/forums/index.php/topic,127789.0.htmlThere seems to be a problem with large chambers producing unreliable ignition. I don't think this would be a problem if you want to put all your shots into orbit, but may present a problem if you want to be able to see the ball fly. I wanted to have a max range of about two hundred yards as that's about how far I can still see a ball.
I roughly followed DoubleD's dimensions and ended up with a mortar with a 1/2 dia chamber about 1" deep, not counting the 30 deg ball seat and just over a 2 caliber length bore, counting the ball seat. The vent puts the fuse into the very bottom of the chamber It holds approximately 50 grs of FFG and I figure the ball goes about 250 yards or so. I couldn't actually tell as I was shooting in a couple feet of snow and it made it real hard to find the balls.
A half charge puts the ball at about a hundred yards making it easy to see the whole flight, doesn't help finding it in the snow however!
If you go back thru the old posts, and look for posts on the golf ball contest, you will find the results of each mortar design and drawings of the mortars that competed.
The best of luck with your new mortar,
MikeR C