Hello everyone! I am new to the forums but not C and B revolvers having just over 30 years experience. I am not a "once in a while" shooter, I am at the range every week and put 7 or 8 full cylinders through whichever pieces I bring with me.
Over the years I have owned and shot ASMs, Piettas and Ubertis. I have read many posts, here and elsewhere about ill fitting caps falling in the works of Colt designs and have had this same issue myself. I have two 1860 Armies, a Walker and an 1849 Pocket as well as a pair of non-Colt 1858 Remmies.
While the Colts are by far more prone to a cap falling into the works, or parts of one, I have had it happen with my Remingtons as well... only rarely but it has happened. Everyone seems to believe that this is an inevitable consequence of the "inferior" Colt design (don't get riled up yet, it is a factor but keep reading). Some advocate pinching the caps prior to placement on the nipple. I do not do this as there is a reason the caps fit so poorly and fall into the works. Whether the manufacturer claims the piece has #10 or #11 nipples the supposedly correct size cap never seems to fit properly because the diameter, cone or length of the nipple, or sometimes all three, is wrong. I have read that this is due to European caps of the same size being slightly different sizes than our American counterparts. I have no direct knowledge regarding a size difference so don't hold me on this but it makes some sense.
These days I never have a cap or part of one fall into the works of my Remingtons and only very rarely in my Colts. I have put seven full cylinders through my Walker and Armies in a single session and not had a single failure from a wedged cap. Even my Pocket, the most notorious jammer I have ever had, is now almost flawless. The first thing I do after ordering a new revolver for my collection is to go to Track of the Wolf and buy a new set of nipples. As soon as my new revolver arrives I clean it and throw the factory nipples away and replace them with the "truly" #11 nipples I just bought from TofW (I never buy #10s, even if that is what the gun shipped with, why buy two sizes of cap?). These nipples are designed to be the perfect dimensions for #11 caps and the caps stays secure even after firing. As I said, there is still the occasional jam but this is the exception and not the rule. Being able to fire all 5 chambers in my Pocket without having to dig parts of a cap out from between the frame and hammer is shear bliss for a BP enthusiast!