Causes of "Chain-fires"
I’ve only experienced a ‘chain-fire’ with a blackpowder revolver once, and that was over 30 years ago. Although I followed Brannen’s advice above, and insured that when the balls were seated, that I shaved off a ring of lead, the one thing that I failed to do on that occasion was to close off the chambers with grease (Crisco). The revolver was a Model 1860 Colt Army made in the late 1960s by Replica Arms, and as always, I pinched each cap when loading so they would hold better. I don't recall that anyone had yet determined conclusively that "chain-fires" were caused by undersized cones or loose-fitting caps, but given that both No. 10 and No. 11 caps were then commonly available on the commercial market, perhaps this may account for this consideration of undersized cones or loose-fitting caps?
Although I have owned and shot many other revolvers in the years since, Remingtons, Rogers & Spencer, and currently shoot a M1851 Colt, I’ve not had any other “chain-fires” (knock on wood) since adopting these same safety measures. Of course, with my Colt, I’m only using a tiny charge of 8 grs of FFFg with a .375 dia round ball for 25 yards. It’s just enough powder to propel the ball to the target with the tightest group. Some others use 15-20 grains to do the same. While I have tried using the pre-made nitrated paper loads, these always worked fine for "blanks" but I also usually had a spare cylinder that could be loaded ahead of time, and I could just swap out when I exhausted the first six shots. Oh, and I still have the above Replica Arms revolver, though it's long since been retired. I once had a chance to sell it but declined, when the late Turner Kirkland, founder of Dixie Gun Works, saw the revolver at the nationals in the late 1970s, and asked "How much do you want for the original?"
First Cousin (7 times removed) to Brigadier General Stand Watie (1806-1871), CSA
1st Cherokee Mounted Rifles | Principal Chief of the Cherokee Nation 1862-66
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