Well back to the drawing board, you guys have given me some homework. I have had that sucker apart at least 5-6 times another go around won't hurt. I even had the breech plug out. This time I am gonna use some new ideas. I will measure from the breech plug face to the flash hole. Then put the breech plug back in and measure from end of barrel to face of breech plug. Then put in 70 gr. black powder and measure again. Then measure my ball and patch and see if somehow I am blocking the flash hole with the ball and patch. I already done every suggestion you guys have given me except that one. I even flashed my powder off on a dry board to make sure it was ok. Thanks again I will be back with my report after this further test.