Your problem is the relationship of the hammer to the nipple. You are leaving off a vital part of the conditions that your rifle won't fire by not returning the complete rifle. If you send in just the lock, Traditions won't be able to fully troubleshoot the problem.
As stated earlier, you need to get the load removed from the barrel.
Part of the basic muzzleloading rifle skill set is the ability to unload a rifle using the ball puller or the CO2 discharger. $30 is good insurance to offset all the time spent trying to figure out the problems.
Another part of the basic shooting preparation is to fire a couple of caps to make sure the flash channel is clear before loading the rifle. When you get your rifle back, promise us you will fire at least two caps to verify the firing system is functional.
That makes a lot of sense. I did that with my Walker to check ignition. I didn't like the factory nipples either. Replaced with SliXShot stainless steel ones. They are made for Remington #10 caps which I have. Hind sight is 20/20 tough. You really don't expect a brand new rifle to not strike the percussion caps, but what you suggest is good practice for sure. I knew I wasn't going to shoot my Walker till I had tuned it, de-burred, polished and the arbor shimmed. If not for that, I may well have been in such an excited rush to shoot it, I might have loaded without trying with just caps. I've also read that capping and firing with the bore unloaded is good practice to burn/dry, and remove and residue oil or moisture prior to loading. I'm going to make that a habit every time I shoot now. Excellent advice as always. I'm learning tons about black powder shooting on this forum. And it is going to help keep me from making many beginner mistakes with black powder.
I have looked at those CO2 un-loaders. I have air soft and pellet guns, so I already have the cartridges. I will probably get one at some point. Sooner better than later if I really get into this muzzle loading. I've got the screw in ball pullers as well. Sooner or later I have a misfire, that is certain. It's not that big a deal with the revolvers, especially the Colts. I have already put round balls into the chambers and measured them with digital calibers and micrometer, it was easy to push the balls out with a hard wood dowel through the nipple holes. I pushed a ball trough the barrel from the breech to muzzle as well and measured it, also checking to see if it had an tight spots in the bore.
I hope Gowacky gets the issue resolved to satisfaction. It drives me nuts when I have troubles like these with a brand spanking new gun, tool, electronic device. I know it's what warranties are for, but still it ticks me off and leaves me feeling like, why me?
It will be interesting to see what Traditions comes up with. We all want answers now. I'd let them know the muzzle loading forum members want to know what went wrong. The fact that quality control dropped the ball on this rifle is pretty much a moot issue now. I'm confident Traditions will make it right.