Blackpowder FAQ

[Lars]

As already noted by sundance44s, the caps are almost certainly not fully seated on the nipples. His suggestion is one way to deal with the situation.

I prefer a different siduation. That is, make sure that the nipples and caps are properly mated to each other. When properly mated, they should fit down fully onto the nipples and fit so snuggly that they will not come off unless pried off. I achieve this by "machining" the nipple cones to fitt the caps.

It is also possible that the nipples have become battered to oversize by dry firing. IF SO, that can be checked and fixed simply. Take ALL the nipples off and see it there is any evidence of a small lip on the end where the cap goes. IF SO, put the big end of the nipple -- the threads that go into the cylinder -- into an electric drill (taking care to not bugger the threads). Then start the drill as the slowest speed and touch a small, flat-sided file to the buggered area until it is removed. This should get the nipple cones back very close to their original shape. Try the caps on them again. Check to see if the caps go fully down onto the nipple cones BUT, do not fall off, requiring to be pried off.

IF the nipple cones are simply too big for even your largest caps (check then, do not just assume from the numbers) then the same drill and file method can be used to make them smaller. IF you do this, go slowly and check often how the caps fit.

Lars

[sundance44`s]

Just an after thought ..of course we don`t know with out seeing them .. but is there a possibility that this gun has been dry fired alot ( cocking and fireing with out caps on the nipples )  if so the nipple heads could be badly mushroomed .... might check this ... could be ..