Hi G Dog, the Paterson arbor is 0.004" smaller diameter than the opening arbor hole of the barrel, 0.434". There theoretically shouldn't be a fit problem if the barrel hole is actually 0.004" larger for the full depth. I ordered a 0.434" reamer to make sure that the hole is the same dimension all the way in.
I have noticed that the metal of the barrel at the rear of the wedge is coining and narrowing the barrel arbor hole at that location. A file was used to remove the excess metal from the inside of the hole at the wedge opening. Shooting the Paterson has required the wedge to be seated deeper after every shooting outing. I have already widened the wedge a number of times to have a snug barrel fit to the arbor. I'm beginning to wonder if 20gr powder loading is too much for the Paterson.
My last shoot tested lubricants. Lubricants didn't do well to minimize fouling. It's time to go the other direction and try no lubes at all. I will load up the cylinders with different powder, 15gr. Triple 7, Black Mz, and Olde Eynsford will be tested to see if there is a powder that minimizes fouling when no lube is used.
I have seen other reports were removal of the Paterson barrel was difficult because of fouling. The rear of the barrel bore opening is flat. Later Colt designs created a forcing cone and a narrow external end at the forcing cone. Colt also added a spiral cut in the arbor to take up fouling in later gun models. In hindsight, the Paterson was a revolver with design failure built in. The Paterson put Colt into bankruptcy.
Regards,
Richard