As a general rule I always found what drill bit size would fit as tight as possible and still go through the hole on the end that threads into the drum. Then I drilled it out with the next bigger size. I use a little bit of never seize on the clean out screw so I can remove it after every range/hunting session. This allows me to be able to be sure the entire breech area is thoroughly clean as well as the barrel.
I have several thousand rounds through my GPRs with fewer than a handful of misfires or hang fires. I think it is due the level of care and cleaning I apply to my muzzleloaders. Also I try to use the hottest caps I can find, ie the CCI #11m. Although recommended for the replica powders, I find it works just fine with the Holy Black. Prior to the #11m, I always used the CCI #11 caps as they gave me the most reliable ignition over the years. ymmv