I agree, why limit yourself to buying those things in plastic bags, you can buy a yard of material that will make several hundred patches for the price of one bag of the pre-cuts. Those things sit in the store so long the lubricant breaks down the fabric so that the patches tear or cut very easily. And the convenience factor is zero, perhaps even less.
I cut my patch material into long strips and hang a strip from my shooting pouch. After dropping powder I lay the end of the lubricated strip across the muzzle, start a ball just below flush, gather up the material in my left hand and with a sharp knife in the right I slice off the excess material. I thus have a ball perfectly centered in a patch no larger than it has to be. For 90% of my shooting the lubricant is spit because I've never found anything better, it's free and I never forget to take it along. I don't swab the bore between shots because with spit patch it is being swabbed with every load. I just wet the end of the fabric strip in my mouth before laying it across the muzzle. Buying material by the yard gives me a great variety of thicknesses and weaves from which to choose what works best in one particular barrel.
But for starters the .490" ball and .018" pillow ticking patch with spit lube will load easily in a T/C barrel. T/C barrels are not "tight", they consistently mic .500" land to land. However, T/C and others do have shallow grooves only about .005" deep so the groove to groove diameter runs only .510" or less. This is because they are a "compromise" bore for use with both patched ball and conical bullet. A true roundball barrel like "Green Mountain" will have grooves more than twice as deep. The same .500" land to land in a Green Mountain barrel may run .526" groove to groove and thus can use, in fact NEEDS a thicker patch.
Do be sure to avoid synthetic fabrics, use only cotton or linen. Linen is a harder material which doesn't compress so much as cotton so you'll want linen fabric a bit thinner than cotton. Linen fabric of .014" loads tighter than cotton of .018" thickness. Linen will hold up well with loads or rough bores which reduce cotton patches to lint balls.
