On big bullets for cannons, here's an example of some from a mould my friend machined years ago for a BP barrel made from a ~3' long 20mm barrel section with threaded breech plug. The bigger one, which we decided against firing, is 2.5" long and weighs 2700 grains. The shorter is 1.9" long, and has a parabolic-shaped base .600" deep. It weighs 1800 grains. The mould had an adjustable-depth base plug to cast different weights/lengths. The hole drilled in these here was to be for a hardened steel rod; we never got a chance to try it on plate though.
To test fire, we strapped the barrel to an old FN machine gun tripod with hose clamps (I know, sounds like a bad yootube video). I can't remember what charge we used, but it was pretty stout. The bullets were lubed with Crisco.
Unfortunately, we didn't have time to do much accuracy testing before it went to the guy it was built for. The bullets did go to within about a foot or so of where we were trying to hit at ~200 yards though. I was impressed, considering our 'high-tech' setup (I'll scan some pics when I get a chance).
I'm thinking about making a similar style mould for my 12 ga muzzle-loader.
Any thoughts on designs for accurate bullets, loads (lube, wads, powder, ignition, etc) for big bore rifled muzzle-loaders?
What's nice for the small bore rifled cannon I'm thinking about building is the variety of off-the-shelf projectiles available. Developing an accurate load should be interesting...