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I find a lot of out of round cbamber mouths when reaming them and have wondered if that does not contribute to it as well. Also I have noticed that very often when cutting a lead ring off over sized balls when pressing them home, the ring will often not be complete. My thought is this is a gap in the lead ball seal.The guy who wrote this article on preventing chain fires, among other black powder subjects, experimented to cause chain fires. Loose caps did not once cause chain fires when he intentionally used them extensively to try initiating them.
Throughout his testing, the one thing he found in common with chain fires he could cause was powder getting crushed between the ball and chamber wall. He diagramming what happens here:
View attachment 169804
The rest of the article is at this link:
http://geojohn.org/BlackPowder/bps2Mobile.html
It's a really interesting read, as are the rest of his articles on black powder shooting.
I've never experienced a chain fire in five decades of percussion revolver use , have had caps fall off loaded chambers many times while shooting a cylinder full so am beggining to question if chain fire is really caused very often through the nipple.