I have three TC flint locks. Two older ones and one brand new one that I have had for three whole days. The new one, and every other new one that I have examined, seem to have weaker mainsprings than the old TC locks. Comparing my older locks with the new one, the tumbler also appears to be different on the newer one, when the hammer is down, the mainspring is extended about 1/8 inch more than on the older locks. The tumbler at rest has the "tail" located further back. The old mainsprings are smaller in diameter and fit closer to the mainspring rod. My old mainsprings measure .248 in Diameter, the new mainspring measures .257 in diameter.
I have no complaints about the older locks other than the soft older TC frizzens, have hunted for 19 years with them and have found them very reliable with a good english flint and a hard frizzen, either Lyman or the newer TC frizzen. I have worn through the hardening on one new TC frizzen, they are not hard clear through, but the hardening goes much deeper than on the old ones. I had it rehardened, and it now sparks great, better than it ever did.
I like the length of the newer TC hammer, but not the profile. I took a file to my new hammer and changed the profile to mimic the old style hammer. I then cut two coils from a spare mainspring and added it to the mainspring rod. The new lock now feels similar my two older locks in cocking effort. It sparks very nice, waiting to get my converted New Englander barrel back to try it out.
This picture shows the new style TC lock on bottom and the old (circa 1990) TC lock on top. You can see in this picture my modification to the new hammer shape to the style of the older hammer.
This picture shows the backside of lock plates. New lock is on the bottom. You can see that the tumblers tail is further rearward on the new lock. Also visible in this picture on the new lock is the extra two coils of mainspring I added next to the tumbler. If you look at the "tail" of the tumbler, the old lock has the tail below the centerline of tumbler pivot trough bridle, while the new lock has the tumbler tail below rear edge of tumbler pivot where it extends trough the bridle.
Finnwolf, if I understand you correctly, it sounds to me like your lock was working fine, your main charge was not igniting but the flash powder was. This is not a lock problem, sounds like the vent was too small, plugged with debris, or not positioned correctly. Other than polishing the pan, corrective steps for this issue do not really involve the lock. And, the sawn TC "flints" are poor performers. A good english flint is the way to go in my experience.
I now hunt mostly with a Haines style longrifle with a Large Siler I built a year ago, but bought my first TC flinter back when I was 16 and it was all I could afford. It served me very well for nearly two decades, and I would not hesitate in the least to take it today on an important hunt.