I have an idea bouncing around in the back of my head for an odd muzzleloader.    I'm thinking about around 32 caliber.   Would that need .320?   310 round ball plus patch?

Not really sure what you're asking, but goggled "32 caliber round balls" and they are .315.

Are you going to patch it?

I got a small lathe.  I'm thinking about things I can make on it.   I had a warped idea that involves a small muzzleloader which would probably end up being smoothbore since I don't have rifling capability at this point.     My thought was to make a 32 caliber muzzleloader and am thinking about what size it needs to be.    Picture a baseball bat shortened a lot (about 7" total) made out of stainless steel w/ a 32 caliber hole in the end.   I'm thinking treat it like a cannon w/ a fuse.   I've got a piece of 2" x 7" stainless steel to make it out of.

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That was my thought, but while I've shot a fair amount of muzzleloaders over the years they were all rifled.   Right now it's just an idea w/ a chunk of stainless steel waiting for a design or complete idea.