I have a flintlock…large siler lock…that gun went through flints like they were going out of style. Maybe get 8 or 10 shots per flint, lots of times 1 or 2…if that fricken gun wasn’t so darned accurate, I would’ve sold it. I tried everything, different sized flints, bevel up, bevel down, took the lock apart and cleaned and polished it…which surprisingly made it worse.
Years later I went to a rendezvous here in Colorado, over at Ft Lupton and I was talking with this guy. During our conversation, I told him about the problems I was having with one of my flintlocks. He pulled out his pistol, handed it to me and said **** this here gun. When I cocked that gun, it was effortless and silky smooth. And it sparked beautifully. He gets about 60 shots on a flint with that little pistol. He told me to take my lock off the gun and remove the main spring and start removing metal from the long arm that engages the tumbler (?). Safer using a file and harder, but if you use a sander…go slow, dip into water frequently, do not heat the metal anymore than necessary. Put the lock together, test it, and then take it apart and repeat until it is effortless and silky smooth.
You don’t need a huge amount of force to shave steel with a flint. You need just enough force to drive the flint down across the surface of the frizzen, and that’s it. If you look at your frizzen and you see horizontal lines across its surface, near the top, where the flint first strikes…it’s hitting too hard, gouging into the frizzen and bouncing off and will wear your frizzen and shorten the life of your flint.
I work on all my locks until I can get north of 40 shots per flint then I call it good.