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It could be that a tiny piece of percussion cap is lodged inside the nipple.  I had that happen to me once.  Take out the nipple and try to look through it.  If there is something in there, you should see it.  Run a thin wire through the nipple.

It could also be that the nipple is fine, and you have too much oil or other matter inside the drum or at the breech of the gun that is getting the powder corrupted.


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