Maybe the cones can be rubbed with some emery cloth or super fine sandpaper to reduce the taper a little bit.
Pietta factory nipples are fairly inexpensive, and new ones may work better with RWS caps than the ones on the revolver.
Old South sells them for $6.69 for a 3 pack. --->>> https://www.oldsouthfirearms.com/nipplesrevolver.aspx
Also, it seemed like you could have used a nipple pick when the cap went off but there was a misfire.
It did produce a super bright flash at 6:37 in the video.
Thanks for sharing.
[QUOTE="TheOutlawKid, post: 11791336, member: 250887" im using homemade caps.
Dave, I will bet that a set of Slix nipples will solve that problem. In that you have 2500 of those caps, it would be worth the investment.
I picked up a 2,500 count carton of RWS 1075+ caps from Midway while they had them. They worked perfectly on my Euroarms 1858 Remington. Last night I shot them on a new Pietta Dance revolver and several of them perforated instead of fragmenting. I also tried a cylinder's worth of CCI No.11s and Remington No.10s, and they fragmented normally.
I've never seen anything like this before. In one case there was a tab of copper sticking out which made recocking the revolver difficult, until I cleared it.
Weird.
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Have you considered filling in the hammer notch with JB Weld, or making it slightly flatter?