Just for a comparison, try it with 50 gr. FFg and minie ball. Try filling the base with lube. It is possible that the FFFg is deforming the skirt. If this does not show any improvement, you very likely have a rifle with a questionable barrel. Then you can go for an aftermarket replacement from one of the custom shops, or a barrel liner.
You might also check the muzzle to see if the crown is damaged. If this is the case, it may be something as simple as recutting the crown to get it going. Many of those were damaged using the steel ramrod and whacking the sides of the bore.
Lots of luck.