Can’t even remember how many broken or rusted in place cones/nipples I saw and had to get out of NSSA barrels over the 23 plus years I worked the Spring and Fall National Championships. I could COUNT on at least two or three per shoot. One shooter with a Mississippi rifle never took his nipple out for years of shooting and by the time I got the nipple out, there was not enough intact metal in the barrel threads to hold another nipple as the rust had eaten that much of the metal away. That problem was solved by having a machinist make a standard musket upper portion of the nipple, but with an oversized lower threaded portion. Oh, and a good half dozen to a dozen of those nipples WERE Ampco nipples that were never pulled and cleaned for years.
NSSA shooters usually do NOT shoot heavy loads. Actually, the somewhat normal accuracy load is about 28 - 32 grains which was half the service load of 60 grains.
When I became the Team Armourer for the U.S. International Muzzle Loading Team, I most strongly recommended that all nipples be Ampco AND the shooters change their nipples at least at the beginning of the shooting season every year. As I informed them, it is best to have a fresh nipple in the gun and shoot it enough to ensure the new nipple did not upset their accuracy load.(Yes, that can and has happened.) I told them they DID NOT want the nipple to go out DURING an International Zone Shoot or worse, a World Championship.
And, yes, even in muzzle loading world there are people who do not listen and pay heed to their Armourer.
Sure enough about 9 months after my warning, we are in Wedgnock, UK and one of our best Female Shooters had the nipple go out in her original under hammer target rifle. It was an Ampco nipple, BTW. I was on my way back from the “necessary shack” when I found her frantically going through all the original and reproduction nipple wrenches I had laid out on the picnic table that was my “work bench.” I calmed her down, took her rifle and fortunately the nipple came out without too much difficulty. Thank Heavens someone had rethreaded the original barrel with the modern ¼ x 28 thread and I had a new nipple installed for her in short order.
This Lady and her husband were both, individually, long time friends of mine, so I had her sit down and calm down a bit. I asked her when she had last had the nipple changed and she said, “I think it was last year.” I had her drink some water and then informed her, “Well, THIS time I hope you listen to me!” She grinned. I told her I wanted her to take 10 well aimed shots at each target and distance she shot to ensure he accuracy load was still good. She did and the rifle came right back to the proper group size and group placement.
I would love to tell you she won the Gold Medal that she had won in the past and was capable of doing, but she only won the Silver in the 100 M Ladies prone rifle match. She got beat by the Wife of the Swiss Team Captain. That was bad enough, BUT I had brought the lock on the Swiss Lady’s original percussion Jaeger rifle back from the dead after some puke (who called himself a gunsmith) had butchered the tumbler and sear with a snag grinder. The Lady on the U.S. Team was NOT very happy with me for a few days after that”¦”¦..
Gus