Welcome to the wonderful complicated world of revolver timing.
Yes, it
is a lot of info to digest. However, the seemingly simple timing of the colt style hammer/bolt ramp/hand/bolt and springs combination is almost as complex as a watch escapement movement.
Whilst Reading about it is needed, plain raw practice and experience is also required until a thorough understanding of the mechanics is acquired.
Pettifogger and Rifle (aka Wayne) are two resources I treasure. Every time they post anything related to tuning I download and archive it to CD.
I also cannot emphasize the two two books enough, especially Kuhnhausen. Buy Kuhnhausen. Read Kuhnhausen. use Kuhnhausen. Eventually you may come to disagree with Kuhnhausen about certain specifics but that will only come with vast experience. And even then you may be wrong
.
Further, whilst I am sure you feel you explained everything completely, it really is difficult to time a revolver for you remotely by web
... no offense, but there are little nuances that are difficult to completely explain without the work in my hands.
For instance, you explain "Again, at full cock the nipple is slightly off alignment -- to the right of where it should be. also, after rotating the cylinder a couple of times, it totally locks up."
This implies that the cylinder is rotating too far (hand too long) but also bolt is not engaging the bolt notch, otherwise the nipple would not move past "dead dead center"
and the hammer would not come to full cock.
You also did not completely explain "what broke". You wrote "The hand and spring had broken" . Which was it, the hand or the spring? If it was only the spring (most common breakage), one can "sometimes" replace that part only.
Now having said all that, and having done this a few times with various vendors colt replicas, it
sounds like you need to gently remove a tish of material from the tip of the hand. However , if the old part worked flawlessly, get your dial caliper ( you don't have one?) and a very strong magnifying glass and compare the length of the old one to the length of the new one. You want to replicate the length and shape of the old one
exactly.
Do not change any angles. Do not round any corners until you understand it all. do not polish with a buffer. Take a
little off, then try it. repeat until success is achieved. It is a slow and iterative process.
To give you an idea of this complexity, whilst it seems that the hand just shoves a gear (the cylinder ratchet) "up" in actuality the relationship and angles of engagement and actual part of the hand tip and ratchet surface that engage each other change continuously as the hammer is cocked. Some folks like to change the tip of the hand from a "flat" to a "point" . do not even consider this until you have done a bunch of these and have perhaps 2 or 3 dozen hands in your parts box. To further complicate matters the strength of the hand spring will also change the angle and amount of engagement. If you continue, At some point you may well start making your own hands. Or not.
In one way, those of us who putz at this will often say "it ain't rocket surgery" ... however in other ways it can be.
You also started by saying you aren't very mechanical, so perhaps this is beyond your present skills?
Don't forget, the book learning and research is essential, and google is your friend.
hope this helps
yhs
shunka