Are you clearing the vent with your vent pick after loading the powder charge, and seating the PRB, but before priming the pan?
Its the Heat from the priming powder that ignites the powder in the barrel. If you don't make a hole in the powder charge with a vent pick, so that the heat gets into the barrel, Its my personal experience that, without opening a hole in the powder charge, and clearing the entrance to the TH, ignition can be "iffy", as you describe, with a HOST of factors affecting whether that charge will ignite. :hmm: :idunno: :surrender: :hatsoff: :hatsoff:
I went through this frustration with my FL rifle, and its Cochran lock. The pan is relatively narrow, and the TH is in the "sunset" position to the line across the top of the pan. I consulted my local BP gunsmith and Gun builder repeatedly through the ordeal, slowly opening up the Vent with ever increasing larger drills, beginning with 1/16" and ending with 5/64". I was opening a hole in the powder charge with my vent pick every time, and still had misfires, and hang fires, occasionally. They stopped when I reached the 5/64" diameter. I use 2Fg powder in the barrel, but prime with either 4Fg powder, on the range, or 2 or 3Fg powder in the field- whatever I have on hand. All the hiccups were experienced on the range using 4Fg priming powder. I don't seem to have any problems with ignition anymore, as long as I pick that Vent before priming, and keep the prime below the TH( vent) In that lock, it takes about 3 pumps of my Priming gizmo to put enough powder in that narrow pan to do this. :hmm: :thumbsup: