Good Afternoon Boonedocker,
Frequently, misfires in percussion rifles are due to internal design features regardless of whether or not a patten breech or drum and nipple design is used.
I have just returned,unused, a very popular custom Hawken patent breech to the maker becuse of an ignition with my friend, Rabbit03's new Hawken rifle, "Big 58"
This breech is probably the best quality and properly correct Hawken breech of it's type available today. The exterior casting is superb, and the fit-up of the tang and breech is first rate. The threads are properly cut and square to the breech shoulder.
Yet inside, there is, in IMO, a design error. Elsewhere on the Forum, Toney briefly described the ignition problems we experienced with his new, "Big 58".
Here are the specific details, and they apply to my Hawken breech from the same company.
To begin with, the junction or intersection of the tap-drill hole for the nipple and the flash hole to the internal powder chamber is extremely restricted, almost non-existent. It appears the nipple tap drill hole was not drilled deep enough to completely break into the flash hole leading to the powder chamber.
This is a fault that should be easily corrected at the factory before the tap drill hole is threaded for the nipple.
In the case of Toney's rifle, I was able to use a very small diamond-imppregnated bit and Dremel Tool to enlarge this opening to a much larger size. The Dremel Tool was used because of the concern a drill bit might "run-out and damage the the breech threads for the nipple.
This alteration was succesful, but did not completely stop the hang-fires and no-fires. Since we were working on a short time frame, we took the expedient route and vented the breech. This has solved 95-97 percent of the problem, and Rabbit03 has has excellant success on the competition line with his "Big 58".
Pesonally, I do not like a vented breech or drum.
However, in the hunting field, only 100 percent sureness of ignition is acceptable. We are not yet assured of that with Toney's rifle.
Since the intervening time spent working on Toney' ignition problem, I have spent time studying my own Hawken breech plug and believe another modification in design might completely solve the rest of the hang-fire/no-fire problem.
The powder chamber inside the external breech threads is drilled and finish to a very shallow length or depth, whichever term you prefer.
This creates a very long flash hole between the nipple and the back of the breech plug powder chamber. In my IMO, this flash hole is way too long and promotes powder fouling blockage in the flash hole. This is the reason the venting of the breech worked so well. The back pressure of the powder charge keeps blowing the fouling out of the flash hole back through the vent hole. Well..., at least it does 95-96 percent of the time.
Again IMO, by redrilling the powder chamber deeper, maybe as deep as the length of the breech plug thread tenon, the length of the flask hole will be greatly shortened. This cannot but help improve the ignition and also shorten the ignition time.
Of course there is a safety factor to consider with this particular manufacterer's breech.
Got to cut this short right now. We are starting to have rain and lightening, and need to shut this computer down.
Best regards and good shooting,
John L. Hinnant
(To be continued)