OK, here are the two photos mentioned after turning the flint over. First is hammer cocked:
It looks a lots better - I think anyway.
Next is the hammer in fired position - it sure looks like the tip of flint is a long way from pan, but is pretty much over the flash hole (center of pan?).
I just checked and the .375" balls for my 36 cal Navy fit nicely when they are wrapped in a pre-cut patch that is.... linen? And about .020" thick for the layer of cloth. Place circle over bore, put ball on top, press down. Doesn't need a starter rod, but just smooth pressure to seat ball on power.
With 3F power in horn I can put the charge in barrel, shake the barrel a bit with pan side down and pan fills nicely with powder. Fun to shoot! Next is to do some actual target practice with it. Tonight I'm just shooting in back yard - nice not living in city limits!
Thanks again for all your help, and please comment on these last two photos. Oh, this lock is fully cast, I don't see any stamped parts at all.
Ken H>