Mull, one trick i have found that a SMR i built likes is for me to leave the vent pick inserted when i powder and seat the ball. fires every time if this is done. if i pick to clear the vent, then charge, then pick again i will have about 20% flash in the pan.
something about the pick leaving a flash channel through the charge i guess.
something you may try.
my flintlocks all have 1/4x28 vent liners with 1/6 vent. i trim the liners flush with the inside of the barrel, cone and polish.
i place the vent hole 5/32 ahead of the breech plug if it is just a flat faced plug. and that's all i use so thats how i do all of them. the liner threads just clear the breech face by a whisper. if i do it right