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I have a Uberti 1862 .36 police that's fine, my 1851 .36 Navy the barrel contacts the front of the cylinder if the wedge is pushed all of the way into place, binding up the cylinder.

Popping a cap on a freshly cleaned barrel won't do anything. A short started round ball with a proper charge tends to rupture the barrel at the point it's obstructed - this ones split down to the breech. I would guess either smokeless powder was used or an overload of bp plus a heavy conical to...