The concept of attempting to install a fully loaded conversion cylinder into a waiting frame gives me pause. It looks like the firing pin nubs are somewhat recessed, but drop one on gravel and all bets are off, and guess where it's pointed if it does land on a small rock.
Shheeesh.
I'm gonna come off sounding like a know it all, but I have been shooting my old EuroArms 1858 with Black Powder cartridges for close to 20 years now.
OK, just for fun, I put three Schofield cartridges into my R&D cylinder.
Yes, the firing pins in the loaded chambers are protruding a little bit more than the pins in the unloaded chambers.
Here is a side view. Now guess why I am holding the cap so tightly against the cylinder. Because there is nothing that keeps the cap attached to the cylinder. All there is is the alignment pin in its hole, and the center of the cap fits into the arbor hole in the cylinder. This keeps everything lined up, but there is nothing fastening them together. When installed in the revolver, the frame keeps everything together, but if one were to turn the cylinder upside down, the cap with the firing pins would fall right off. Would the cap stay in place on the trip to the ground if dropped? I have no idea.
Here is the best way I have found to either remove an empty cylinder from the revolver, or pop a freshly loaded one in. I always hold the revolver horizontally, just like this. One hand holding the revolver, the other hand, which is not normally holding a camera, handles the cylinder. Because of the position of the hand in the revolver, the cylinder can only be removed and replaced at the right side of the frame, not the left side. Also, I don't reload out in the field where I might drop the cylinder all the way to the ground. When shooting this revolver in CAS, all loading and unloading gets done at either the loading table or the unloading table. So at worst, if I fumble the cylinder, it will only fall a few inches to the table. Not enough time to build up enough velocity from gravity to set off any primer that might happen to be struck by a firing pin.
Yes, with the six shot R&D cylinder, the chamber walls are quite thin. About .038 at the thinnest spot.
Has anybody ever seen how thin the chamber walls are on a Colt? I don't recall exactly how thick the chamber walls are on this 2nd Gen Colt, which is fully proofed for modern Smokeless 45 Colt ammo, but I can tell you the chamber walls at their thinnest points are about the same thickness as with the six shot R&D conversion cylinder.
I never load more than five rounds into my 1858 with its R&D cylinder anyway, we are not allowed to load six at a CAS match, so I have never had a problem with loading five and keeping an empty chamber under the hammer.
Lastly, one of the main reasons I went with the R&D cylinder all those years ago is it required absolutely no modification to the revolver. Pop the C&B cylinder back in and it is a non-firearm again. Pop the cartridge cylinder in and for as long as that cylinder is in place it is a cartridge firing handgun, subject to all Federal and State regulations. It is so easy to pop out the cylinder to reload and pop a fresh cylinder in, just like Clint did.
And yes, if you permanently modify the frame, by cutting a loading gate, it is no longer a non-firearm, it is a cartridge firearm forever, subject to all federal and state regulations.
P.S. I remember how nervous I was the first time I fired a replica of the 1860 Henry rifle. I had heard all the stories about how if one dropped ammo directly down the magazine tube, it might fire, or if one lost their grip on the magazine follower it might slam on top of the rounds in the magazine and set them off. Yes, this has all happened. But when I bought my own 1860 Henry about ten years ago, I learned how to handle it safely so none of that stuff would happen. If one is brand new to any firearm, one may get nervous around it. But with time, good habits develop.