Tim - I'll try a slightly longer flint and see what it does. Perhaps just move the existing flint forward a tad for testing?
HH: Interesting you should mention the flash hole is too large - I didn't think of that. I just thought it was convenient it self-primed the pan from the barrel. I measured the flash hole this morning and it's right about .099", could be .100". The hole is low enough down the pin gauge hits edge of pan before sliding thru the flash hole, but could tell pretty close the flash hole diameter. I understand the typical flash hole should be .060" to .070" range?
How drastic is it for the flash hole to be so large in mostly a "wall hanger" pistol? This pistol will get shot less than 50 times/yr I'm sure, perhaps less once the new wears off. As mentioned before, it was purchased to hang in the display case alongside the Bowie shown in photo in first post of thread. I can't have a gun that can't be fired!
Thanks again to all for help and guidance.
Ken H>