Polish the frizzen smooth. Try to see if your lock sparks, now. If not, the frizzen many not be hardened properly.
you can do the hardening yourself, with Casenite. Buy it from Brownells, or some of the other suppliers. You want to hold the frizzen in the jaws of your vise, steel to steel, and heat the front side of the standing frizzen. That is, put the torch to the back, or forward side( Now underside), of the frizzen as it sits in your lock on the gun. The frizzen will slowly redden and then go to orange, and white on the face. The face of the frizzen should be UP, and parallel to the floor.
Pour the casenite onto the face of the frizzen, continuing to heat the frizzen from underneath until the casenite " melts" into the metal of the face. Repeat pouring on more casenite, until it no longer takes any more. With the frizzen hot enough, the carbon will migrate further and further into the metal, until you have a very thick layer of steel that is hardened.
When you can't get the frizzen to take any more casenite, let it cool.( Some recommend dumping the frizzen into water that has been heated to about 120 degrees, to knock off the scale that forms on the frizzen from the hardening process. Otherwise, you may need to use a powered wire brush, or abrasives to remove the scale. Hot water, instead of cold, makes it much less likely that the metal will break from the shock of the temperature change.)
The jaws of the vise will have kept the base and cam of the frizzen cooled, as they act as a heat sink- drawing heat away from parts you don't want hardened.
To protect the hardened upper part of the frizzen from breaking, put the frizzen on a cookie sheet in an oven, and heat it to 375 degrees. Leave the frizzen in the oven at that temperature for an hour. Then turn off the oven and let the sheet and frizzen cool to room temperature. That should temper the frizzen so it will be both hard, and strong- NOT BRITTLE.
I am suspecting that the Angle of Impact of your flint has never been correct, at 55-60 Degrees, measuring along the top of the bottom jaw, to the point of impact on the face. The center point of your protractor is placed at the POI, and the upper arm of your angle, is a line from the center point to the top, rear point on the face of the frizzen. You should notice that the top of the face curves backwards.
Your flint should also be striking the face at between 60 and 66% of the distance UP from the bottom of the frizzen. You need to strike that high to get the frizzen to flip open correctly, and timely, so that the frizzen gets out of the way of your sparks being thrown- not dribbled down-- into the pan. The flint should scrape the face of the frizzen, NOT GOUGE IT.
IF you are getting gouges across the face of the frizzen, or chatter marks( think an old fashioned washboard), you need to correct those problems, whether the frizzen is hardened or not. I can walk you through that, if you send me a PT.