WV Hillbilly: The numirick arms barrels are bored to a flat with a guard ring around the nipple. I guess cause I'm not looking at the gun this is about .50 size hole across the flat. It would reduce the barrel thickness some. Mine is the round target barrel 1" so would not be a problem for me. I can see in some of the smaller octagon barrels it might become one. Now to observe further if the barrel is that thin wouldn't the nipple stick up into the barrel and creat a cleaning problem. If not the nipple threads would have to be very short. Maybe thats why they used the 32 thread to get more grip in the thin barrel. Understand this is just my opinion. Fox :thumbsup:
My barrel is 15/16 inch octagon, .45 caliber, 32" long, and has a brass flash cup installed; but there is no recessed ring where the nipple is threaded into the barrel. So my barrel wall thickness is roughly 1/4 inch. The nipple shank is short enough (or the barrel wall thickness is thick enough), so that it (the nipple) can not extend into the interior of the bore. That would make for some bizarre ignition properties, I would think; aside from causing cleaning and loading problems.
I think one reason they used fine threads is to make sure that the nipple doesn't get cross threaded when started. It also would provide more threaded area over a shorter distance as you mentioned. I can logically see that milling a flat on a round barrel for the nipple makes sense; but the amount of material removed should not be enough to cause a problem. If that is true, then a "shorter" nipple ought to have been selected to begin with.
I don't know how small (distance across flats) the octagon barrels are on the smaller calibers. At least on mine and these currently manufactured Deer Creek guns, ALL the barrels are supposed to be 15/16 inches across the flats. I can't say about the older Numrich mfd. guns or other different models.
I've seen some OLD guns of various types that have really "short shanked nipples" due to their octagon barrels being small. Obviously the designers of long ago also knew better than to extend the nipple into the powder chamber area.
I still think that the nipple "blowing out" had to be from a manufacturing defect (or perhaps an incompetent machinist/operator), the wrong thread nipple being installed, OR the tap used was the wrong size. It is strange that it held for that long without failing earlier though?
IF the barrel wall thickness is truly that "thin", then it has to be re-threaded to a fairly high TPI nipple, or it might happen again. Besides that, keeping the overall nipple length correct so that the hammer face strikes the nipple squarely is important.
Shoot Safely!
WV_Hillbilly