Thank you all for the input. As I said, it WILL fire, slowly, if you fill the pan full. To me, a novice, it seems the sparks cant reach to hole using a small charge...but I'm not an authority.
My biggest fear is he drilled not only too high but at an angle and the hole is sloped upward...when i get it in my shop a drill bit will conform/deny this.
I think before i go further I'll pull the plug and confirm he didn't drill into it. I voiced my concerns to him when the hole was being drilled, but to no avail. Based on what little comparison I have done w/ a cleaning rod I know the hole is close to the plug.
I have used a touchhole prick most times, I don't recall it hitting anything, but I'm not sure and will confirm that.
I have a friend who has a machine shop, if it needs repair I'll take it to him. He also shoots black powder and is well schooled in their construction.
I thought about building up the pan to raise the level of the powder...any thoughts on that ?