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I am VERY familiar with humidity here in Florida and I do think that plays a big part in fouling issues regardless of the brand of powder. In the Spring and Fall, our humidity levels drop down to near "normal" levels and I always have much less trouble with fouling and having to swab after...
The gap between the nose cap and the ramrod is normal. I don't see why it bothers you, the whole reason the fore stock of most long rifles and muskets taper down at the nose cap is to "clear" the ram rod making it easier to grip the ram rod when extracting or re-inserting it in the ram rod channel.
I have ordered stuff from OC from time to time and never had any problem. Heck we all use TOW and they are a much larger operation and have become sort of the standard when it comes to buying our sort of stuff online and Track often takes a week just to get around to shipping out an order.
Historically, the vast majority of guns prior to the mid 1800's were simply left "in the white" mostly due to the added cost that was added by builders or gunsmiths to do a brown or blued finish. The wealthy and the officers probably would occasionally chose to spend the extra dollar or two for...
I have learned to carry BOTH a C02 discharger and a ball puller attachment in my range box and yes, I have actually had to use BOTH in a single day at the range in the past. Clearly - my shooting buddy and I like to chat too much!
I have owned two Invest Arms Hawkins style rifles over the years, one a .54 caliber flintlock and my current one which is a .54 caliber cap lock. Both were very fine guns and shot great. Neither of mine had chrome bores and this is the first time I have ever read that they ever came that way...
I have shot double charged loads with no ill effect and I once shot a double ball load with no ill effect (except a purple shoulder) but I don't recommend either. Just because you get away with something once or even twice doesn't mean it's not potentially dangerous. Glad there was no problem...