Found it! Thanks Black Jack.
With the weather (pretty much rain all the time lately, and when it is not raining the yard is wet), and not being able to find caps locally, I have finally broken out my sharpshooter .22 cap maker. The process is tedious at best, but, it does get the job done. Have to say, if and when caps do become available locally I will buy what I can to prevent running out and having to make my own, but, if the zombies come, I will be able to make caps if I need them.
My formula (thanks to Black Jack and the kid) has evolved to 3 paper caps cut to fit and a drop of duco cement, let dry at least 24 hours.
Tested this process with an 1851 .44 navy (I know not historically correct), 8 grains of BP and a wax bullet in my back acreage. all 6 shot without issue, maybe, just maybe a slight hesitation.
2 caps and without the duco both proved to be erratic.
This worked with both double pop cans and with .005 brass sheeting.
Next I am going to build a way to use my arbor press (or maybe my single stage) to press out caps more efficiently. I like the idea of having a support for the metal so it does not crinkle so bad and slides through easier I saw from someone on here (sorry, dont recall who that was)
The cap making part is not so bad actually, its the cutting and adding the caps that takes me the most time so I do that while listening to forbidden weapons or Mike Bellevue on you tube.
My step by step:
I punch the caps out using my little arbor press from harbor freight - using the ss22 device, and that is better than hitting with a mallet (but watch your fingers, I pinched a couple of mine once or twice)
I snip the paper caps as close to the dots as I can without setting them off (end up with a little square)
Stuff 3 of these in the cap with an long allen head bit from my gunsmithing tool box that is just slightly smaller then then inside of the cap (dot side toward the hammer cuz that is how we loaded them in our old cap guns as a kid)
Once filled, i drop them in an old CCI 22 caliber ammo box (holds 50)
Put in a drop of Duco and let them set for a day or so, then put them in a tin.
if you have one, the CCI .22 box comes with a slide off lid, and under that lid is a plastic piece with 50 holes in it. I pried that piece with the holes out of the box, glued it to the top of the slide out piece and then slid it back on the box, so I have storage under the caps for wax bullets or lead balls, or, whatever (its clear so don't want to store finished caps in it - maybe if I blacked it out).
Any way, these seem to work so far, have not had any failures to ignite in my 1851, though my little cheap philly derringer (Juker) single shot does not reliably set off these caps - maybe the nipple is too small or it just has a weak hammer, it definitely does not hit as hard as the 1851.
In closing, I can't begin to thank the folks on this site, not just for the cap making info, but also for all the other BP info I have learned over the years. There are some wonderful and knowledgeable people here and while I guess I could also blame all you folks for my collection of BP shooters as well, I think Thanks is probably better