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Cosidering what you have checked--Buy several brands of caps to see what seats properly, by firing with caps only. A #10 in one brand may fit tighter than a #10 in another. On my rifles, I frequently have to slightly file around the nipple, as I like RWS caps, which fit my hotshot nipples too tight to seat properly. I hunt elk and deer both with my muzzleloaders--and must not ever have a misfire! I am a muzzleloader rifle instructor at a range, and see this problem fairly frequently--its usually just a matter of matching the right cap to the right nipple. Best of luck....ChuckD By the way--nipples are not expensive---get the best!
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