I was thinking that if one barrel needs rotating to bring it into alignment with the other the nipple won't line up with the hammer....unless it is a minute amount.
Yes, you're right. There is no way to rotate barrels with relation to one another. As you said the nipple wouldn't align, but also there are square hooks on breeches. Also, I use those flats to align the back. Still I managed to solder one barrel 8 thou forward of another (it is shimmed temporarily at the breech - it will be resoldered anyway). If I added rotation to the whole alignment it would be even more difficult for everything to line up.
Regarding the muzzle cresenting....
I know that 5 shotguns I have adjusted the POI on was all done via filing across the thin walled muzzles just so one quadrant was shorter by a mere. 030" and hardly discernable.
One heavy walled gun was bevelled more in one quadrant. They all responded exactly how I wanted. I know that was with shot but for legal reasons and busy bodies I can not report on other projectiles.
I'm just trying to emphasise that it is a tiny amount of metal removed!
To clarify how it is done. I always thought one opens the crown in crescent shape in opposite direction one wants to move the poi. Removing material from the muzzle face to however deep the crown goes (about 30~40 thou).
However, above (unless I misunderstood) you mentioned shortening the barrel at the muzzle slightly in the same shape. Was the "shortening technique" used because the barrel was too thin walled for there being a crown at the muzzle?
Are both ways interchangeable (crescent ing the crown, vs shortening the barrel slightly at the muzzle)?
Also, do you have any pictures of it done correctly? I may think I know what you mean, but I may be wrong.
I made my crown cutter (pictures below) to cut a 45 degree crown. Then when I cleaned up existing crowns I noticed they must have been out of round because they started cleaning up only after I removed all of original surface.
Then I used a lead ball charged with a grinding compound spinned by an electric drill (through a wood screw) to break the sharpness.
When I was done the result looked really nice, but also the transition from crown to the barrel looked very sharp. It didn't feel sharp, but definitely looked the part so having the cutter to redo it if necessary I resorted to a trip of sandpaper wrapped around my finger. I counted the number of sandpaper strokes and moved the barrel around by the same amount so I think I achieved pretty good co centricity. However, human hands are not perfect so I may already have a slight crescent there and not know it. When I go to shoot it I'll take a bit of sandpaper and if I have poi shifted unexpectedly I'll remove a tiny bit of material as Britsmoothy describes. I'm pretty certain I'll have to make two more cutters anyway. One 90 degrees to clean up the muzzles faces and another one shaped differently than straight 45 degrees. Maybe something funnel like?
Anyway, here are few pictures from making of the cutter.
Turning a piece of water hardening steel rod on my "precision(Chinese)" lathe
I have a large 2 ton made in Poland lathe that I usually rough cut stuff with, because it is much more powerful. Then I usually finish the part on the Chinese mini lathe. I normally use a 3 jaw chuck, but I decided to turn this properly between centres.
Then there is a blank done. The pilot fits really nicely. As one barrel is slightly (hal ~. 8 thou) larger it is a slight friction fit in one and a sliding fit in the other. No wobble detectable.
Then cutting teeth were milled. I never made a 4 tooth cutter before so I made it cut in counter-clockwise direction by mistake... No worries. Precision is most important.
Then after hardening (before tempering)
And final picture below being held by a threading handle. The shank is round, but forces involved are so low the wrench was holding it fine.
Then there is the muzzle cut with it. You can also see my high tech temporary front sight.
On the picture the crowns were cut with the cutter about 5 thou deeper than originally. Then the lead ball lap was used, followed by a little of sandpaper wrapped finger. I also stoned muzzle faces.