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Same lock, different vent hole size

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This is another question where I don't necessary need assistance, I just want knowledge, opinion and information. I have two specific flintlock rifles in mind. They each have the same exact lock make and model respectively. I load the same charge in the barrel and the same powder and amount in the pan. They have the same kind of flints. They have touch-hole liners from the same company (although they do have different threads). After experimentation, I opened one touch-hole to a certain size where the ignition is 100%. I did the same to the other, but achieved 100% sooner, with 2 increments less on the numbered bits. Why does the fire get into the smaller hole and ignite perfectly when the other rifle was only about 80% at that size and needed two steps larger hole to achieve its 100%?
 
Same caliber and barrel thickness? Maybe one liner protrudes further or less into the barrel differently than the other. If so might not be getting powder from the barrel close enough to the touch hole.
 
Also the touch holes may be in slightly different locations. Frizzen and cock geometry, springs, frizzen hardness etc May also be slightly different. Even the flint might effect it. Maybe how you hold your tongue is different. It would seem they should be the same, but they are muzzleloaders.
 
Opinion you ask for it. When it comes to flint locks there’s to many variables to be the same. Especially with the flint itself. A flint is like a snow flake with no two alike. The locks may look the same but there’s no doubt some differences.
 
Flintlocks especially are individuals just like...well, women.
A touch hole liner belled on the inside does wonders. If your liner tightens with an allen wrench throw it away. New research shows that prime powder right up to the touch hole even covering it. Test was done with a high speed camera. Think there was an article in Muzzle lasts. NMLRA is a good organization to join. Nice informative magazine. Make sure to scrape your breech with a scraper. Depending on how it's breeched can make big difference on the ignition .Build up can actually block the fire from your pan.Had a rifle do that to me Changed the touch hole liner and scraped the breech goes off everytime. Hope this helps. Keep your powder dry and your whistle wet.
 
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