Since a cap 'n ball revolver is not a friearm under Federal Law, I too use USPS Flat Rate Boxes.
FWIW, I dismount Colt-clone barrels & wrap separately from the cylinder & frame in the single box.
I've never had a damaged gun, "firearm" or not, arrive via USPS yet - in over 30 transactions since the 1980's.
I did have UPS damage a flintlock rifle that someone sent me, that was packaged nowhere near as securely as I usually do - the CB blew out through the wetted end of a cardboard shipping box.
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