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Flintlock can fire from half cock

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Well it sounds like the problem was the tumbler. On the old one- can you tell what was wrong? A worn or broken under cut in the half cock notch?
We are all on a learning curve, all knowledge is good.
 
Update. So I just finally had a chance to shoot this rifle after replacing the worn out tumbler long ago. The gun shoots great !! I only managed to get off 4 shots before my wife came out and said my little guy nodded off for a nap and shut me down. I shot at just 25 yards leaning on the deck railing (not the best rest) and to my surprise I had all four shots almost all touching just at the lower 6 o'clock position in the bulls eye just splitting the ten and nine ring. Best group I ever shot with a flintlock. The rifle is very fast with little time to flinch and I am in love with it. Can't wait to get it out again. Thank you all for your help and advise. Tony
 
There is a good possibility that when you tighten the sidelock screw that it is causing the sear to bind against something. Try this: Put a marking agent ,such as lipstick on the sear arm including the end of the sear arm. Put the lock in place and tighten the sidelock screw and work the action. Remove the lock and look into the sear mortise and see if there is lipstick anywhere inside the mortise. If it is, it shows where the sear is bindng and should be trimmed away.
 
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