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I am finishing up my TC flintlock kit given to me by a neighbor. I did not look closely enough at the lock/barrel joint. (Already had finished the stock)
the gap between the pan and barrel was close to 1/16 “.

I have been working away at lessening it, and now have no more than 1/32” gap. Maybe a hair less.

im going to continue until it is flush against the barrel.

Am I correct?

I was afraid Powder could get down in there, and create a Situation! Not fond of surprises with BP. Or am I overthinking this?

picture shows original gap! Much less now
 

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I would strive to close the gap as to have the lock flat make contact with the barrel flat. Between fine 4F powder finding it’s way through the gap, rain, and the gasses generated during ignition, a good seal avoids potential issues.
 
Yes powder can get down in there and yes it can lead to an unpleasant surprise. 😲 Even if that doesn't happen it will blow fouling down there making for even more cleaning. I suppose it could even bind the lock up but that probably won't happen. I have painted the inside of the lock mortise with a thin coat of epoxy on some of my guns specially a Bess I used for reenacting as well as shooting. That will waterproof the mortise as well as preventing oil from soaking the wood and yes I have seen originals with oil saturated mortises.
 
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