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Nobody, including Hogdon, could figure out why I was getting repeated hangfires with 2f T7. I know , I know ----- use real black!
Not an option. Anyway I figured out my nipple channel was too small so I opened it up a hair and drill a cone on the base of it. More better, but second shot hung and missed the target at 50 yards. Brought some 3f and commenced firing. Not my best but kill zone shots. Target with 3 shots was at 100 yards, other at 50. 90 grains of 3f T7 averaged 1398 for 5 shots. Remember, old man here. Be gentle.
 

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That's better than I can shoot on a good day. I'll say you did all right!

I have very little experience with BP substitutes and will let the more knowledgeable folks weigh in on the ignition issue.

Notchy Bob
 
I'm using a musket nipple from Track and RWS 1081 caps. Track's nipples have a way too small flame vent and have to be opened up or they're worthless. The rifle is my 54 Caliber TC New Englander with Hoyt barrel. 1/48 twist.
 
My musket nipples have a .155 hole leading to with in .080 of bottom. In the .080 bottom is a .032 hole.

The key is getting more flame into the .032 hole.

Some nipples I have bought have a dinky upper hole.
 
Flash hole really doesn't transfer the energy of the cap. A larger flash hole just wears out faster and helps make up for a crappy design flaw.

You want a smooth transition from the flash channel, to the flash hole.

A lot of nipples are rounded at the bottom or can even have an edge that causes the gasses to ledge up and come back at you. Limiting the amount getting into the actual powder charge.

This was a huge issue for folks when the modern blackhorn 209 came out.

Some pictures I collected to give you an idea of a great design vs a poor design.

Take a thin wire and run it down the inside of your nipple, take note of what shape you're feeling, especially at the transition point.
 

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Nobody, including Hogdon, could figure out why I was getting repeated hangfires with 2f T7. I know , I know ----- use real black!
Not an option. Anyway I figured out my nipple channel was too small so I opened it up a hair and drill a cone on the base of it. More better, but second shot hung and missed the target at 50 yards. Brought some 3f and commenced firing. Not my best but kill zone shots. Target with 3 shots was at 100 yards, other at 50. 90 grains of 3f T7 averaged 1398 for 5 shots. Remember, old man here. Be gentle.
I'm using a musket nipple from Track and RWS 1081 caps. Track's nipples have a way too small flame vent and have to be opened up or they're worthless. The rifle is my 54 Caliber TC New Englander with Hoyt barrel. 1/48 twist.
By now we should know that it takes a higher ignition temperature to ignite synthetic powders. Your are doing that by using the musket nipples and the musket caps, but apparently you are still getting hangfires. This telling me that there is something in the flash channel of your New Englander. Bobby Hoyt is pretty good about cleaning the burrs and shavings from a rebore. I would still want to verify that the flash channel from the nipple seat to the powder channel clear. A stiff pipe cleaner is needed to really scrub fouling from the flash channel. The New Englander and any T/C long arm will have a long flash channel.
TC Breech.jpg

The fact that reliability improved when you went from 2F T7 to 3F T7 implies that is still something in your flash channel that is blocking the larger grained powder from getting to the nipple seat. As others have stated, you need a lot of heat to ignite synthetic powders. This can be done using hotter caps. Musket caps have more ignition powder. The magnum version of caps such as the RWS 1075 Plus or the CCI Magnum caps are hotter than standard caps. When combined with the nipples designed to deliver more heat to the powder, such as the Hot Shot, Red Hot or Spitfire nipples, the reliability to ignite synthetic powders is usually improved.

Now clear the flash channel really well. It is quite possible that even a vigorous flush won't eliminate the blockage.
 
I am using TOW musket nipples, RIO musket caps and T7 FFFg in T/C renegade and hawken barrels bored out by Hoyt and I am having no issues.

Try sticking to the finer grain powder as it gets into the flash channel easier when you do the "bump".

The TOW musket nipples pin out at .027/.028. I was using Treso, but after about 20 shots they were getting too large and causing a blow back to half ****. I am also using a much heavier load in 54 cal than you are using however, so the smaller flash hole is what I needed.
 
This is a little off topic but 1398 fps seems anemic for any powder, especially t7. All the subs are prone to deterioration over time especially if not sealed tightly. Maybe try some BP or pyrodex or a fresh container of t7.
 
This is a little off topic but 1398 fps seems anemic for any powder, especially t7. All the subs are prone to deterioration over time especially if not sealed tightly. Maybe try some BP or pyrodex or a fresh container of t7.
Not if he is using 420 485 gr conicals, which I suspect he is.
 
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Clean your barrel and pay special attention to the breech plug channel.
I've never had any problem getting any of the substitute powders to ignite in any of my rifles! Using a regular old number 11 cap.

Every single firearm I get in that has ignition issues.
Number one problem is the gun is dirty!!! The breech area is all gummed up or plugged.
Number two issue with a percussion, there's a spent cap stuck in the hammer.
 
So right you are. Don't know why I assumed balls.

OTOH, I still think deteriorated powder could be an issue.
Especially T7...but I think he said he just bought the FFFg. But it could still be old if purchased from a retailer.

But approx 1400 FPS out of a 28" barrel for a 50 cal 420-460 (I guess I should learn to read and retain better) a 54 cal 485 gr no excuses using T7 FFFg is pretty spot on according to my calculations
 
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Especially T7...but I think he said he just bought the FFFg. But it could still be old if purchased from a retailer.

But approx 1400 FPS out of a 28" barrel for a 50 cal 420-460 gr no excuses using T7 FFFg is pretty spot on according to my calculations
Yeah, I think that would be right in the expected velocity range.
 
I am getting 1530 fps mv using 110 gr of T7 FFFg with 485 gr No Excuses using an oversized OP wad in a 23" barrel.

The New Englander is 26", if I remember right.
 
Off a bench, yes, it might, but I use a gel pad and I have shot well over 250 shots using comparable stout loads in 58 cal and 54 cal working up my Thumper Carbine loads and it isn't bad at all. In your typical hunting stance, sitting, standing kneeling, it is no worse than a high based pheasant load in one of my Spanish SxS.

These loads aren't for recreational plinking, rather to drop elk, so If I shoot more than 1 shot, I ain't doing my part and deserve any abuse.

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70898.jpeg
 
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