Did you dry fire a couple caps before you loaded it? That is one precaution you should always do before loading your rifle. This dries out any dampness or oil if you had just cleaned it.
I have an old CVA cheapie that I prefer to my Thompson inline. It has NEVER failed me here in humid Kentucky.
If you have any Pyrodex.....THROW IT AWAY! Or, if you have somebody you don't like, give it to them..LOL!
Another thing I suggest is to use 3F instead of 2F.
I used to shoot a lot and while I don't claim to be an expert.....I learned a few things along the way. I chronographed my loads......I always shoot a ball, prefer them to concials. I started with 65 grains of 3F and worked up at 5 grain increments. 75 grains gave the best accuracy and velocity. 80 grains gave very little more speed, but accuracy began to fall off as the heavier charge fouled the bore quicker. 85 grains gave no more speed at all. Most of the extra powder was being blown out the barrel and burning in the air.
For the very best accuracy.....run a bristle brush down the bore after every shot....you'll be amazed at the difference it makes. Black fouls a barrel very quickly and the CVA's have shallow rifling..3 or 4 shots and the grooves are filled with fouling. For hunting purposes, you'll be lucky to shoot twice in a day...so it's a moot point. But, if you're target shooting, just run a dry bristle brush down the bore before reloading.
Always snap 2 or 3 caps on an empty barrel before loading it. Hold the rifle out from you while loading it and pour your charge down the barrel...like the other fella said, smack the side the barrel near the breech a couple times to settle the powder and then seat your ball/bullet. DO NOT stand there and tamp the bullet with your ram road. That deforms the soft bullet. Just ram it home in one smooth motion until you feel it seat. You might need a ball starter for the first 3 inches.
I've killed a bunch of deer with a muzzleloader and never had any misfires.
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