Being a super genius, I've managed to flip off an unfired cap or two along with the fired cap fragments... in the field... in the rain... with no spares. But only that one time, now I make sure they're on tight.
Still, I spent some quality time with my ASM baby dragoon and R.L. Wilson's Colt book, and last week I got my repro over to a local gunshop to compare to a few original 1849 pocket and baby dragoons. On my ASM, the capping cutout is a little larger but more shallow, and the clearance cut is both smaller and higher up in the cylinder face. It's very noticable, quite a lot of difference. On cocking, the repro's nipple isn't really lined up with the cutout, it's travelling a lot lower.
So of course, now I had to check the other repros I had handy. Looking at a Navy Arms/Pietta brass frame '51 Navy, the clearance cut is visibly quite large and semicircular. Dixie/Pietta steel frame '51 Navy, it's pretty shallow, and Cabellas/Pietta it's right in between the other two in depth.
I'm not sure what accounts for the difference in specs, but it's there, and visible with the naked eye. Anyone know why this is?