We've gotten off on a tangeant. The Military Board of Tennesse was using an archaic method of referring to the caliber of rifles they wanted minie balls made for by the number of ROUND balls of lead the exact size of the bore that would weigh one pound rather than using a caliber expressed in hundredths of an inch. They WERE NOT referring to the number of minie balls that would weigh one pound when cast from the mold. Today, we would call this the 'gauge' rather than the caliber. A 12ga. shotgun is so designated because 12 lead balls the diameter of the bore weigh one pound. When Meriweather Lewis in his journal described shooting two ducks with on bullet from a rifle of 100 caliber, he was refering to a rifle that took 100 balls of lead the diameter of the bore to weigh 1 pound. In 'An Essay on Shooting, by T. Cadell in 1791, in discussing fowlers :“The Spanish barrels are generally from three to three and a half feet long; their caliber is from 22 to 24*, and their weight from three to three and a half pounds.
* In speaking of the size of the caliber, we mean by 22 or 24, that so many balls exactly fitting it weigh just one pound; and every caliber is marked in the same way.”
In short, if you want to tell the difference between a .54 minie ball and a .58 minie ball, buy some decent dial calipers There is going to be a lot of variation in weight, but if the diameter is greater than .539 it isn't going to fit in a .54 caliber rifle. BTW the modern U.S. Navy uses caliber to refer to the length of the barrel expressed in bore diameters. For instance a 5"-54 caliber means a gun with a 5" diameter bore with a barrel 22'-6" Long.