ok, do I need wadding between the powder charge and ball?
No, not if you have the powder packaged in foil.
I never use a wad between the powder packet and the ball. I
DO tape the ball to the charge to prevent rollout.
(The quarter in the photo is just for scale.)
Others attach a sabot, but this is to prevent ball rollout and in some cases stabilize the ball in flight. This type of sabot isn't intended to create a gas seal.
I think you may find 400 grains behind a cast ball in a 1.25" bore
excessive. I would consider this a
heavy load.
My bore is 1.156" and I only load 250 grains. Any more and the recoil is too violent, so much so that I worry about damaging the carriage. Personally, I would start at about 300 grains, and increase it according to how the gun behaves.
In my experience, the recoil is often the limiting factor. A well constructed barrel can certainly withstand the pressure of a maximum load, but the recoil could wreck a carriage that you spent a lot of time and money building.
EDIT: I've never had that much trouble getting a photo link to work, but it should be showing up now.