'Plastic guns' ( we normally say polymer) have a steel barrel, slide, breech and breech face. The stock/grip is usually a high strength plastic. Examples include the Glock, Smith & Wesson M&P, Springfield XD, H&K USP. The barrel and slide contain the force of the firing.
Not an expert, but I think 4-6/1000s of an inch is the correct setting for a revolver cylinder gap. Someone will correct me if I am wrong.
The mismatch occurs because the timing (alignment of cylinder with barrel when the hammer falls) of the revolver is not precise enough and the chamber is not properly aligned with the barrel, so the bullet partially strikes the frame which shaves the bullet, throwing lead to the side. Poor alignment is the result of poorly fitted parts. Use the How to Check Out a Revolver thread to check your gun.
Proofing was/is the use of an overpressure load to ensure that the gun will not blow up. Guns that have been proofed usually have a 'proof mark' stamped on them. In England proofing was done at an independent facility, Rohm may have been proofing their own guns. Or not.
The main spring that drives the hammer may not be of high enough quality to give enough force to the firing pin strike each time, or it may have been too light to start with. I have a Beretta with a light main spring, it occasionally misfired when shooting .22 rimfire rounds. Years ago I had an Iver Johnson revolver with a broken mainspring. I fabricated a piece from some steel strapping. It worked, but wasn't the best quality! What quality of metal was used by Rohm for their springs?
Any used Smith & Wesson revolver in good shape would be my first pick. Use the How to Check out a Revolver thread to make sure it is OK. Read
http://xavierthoughts.blogspot.com/ for good tips on buying used. Stay away from Taurus, a little research on this forum will show they have a poor rep for bad quality control. Surprisingly, Rossi, which IIRC is Taurus' cheap sister company, has a good reputation. A second hand Rossi that passes the revolver check out would be acceptable to me. Colts tend to be expensive and their lock work is easier to break.
Yes it's possible that it's been dry fired to death. I've personally broken the hammer block in two S&Ws through thousands of dry fires, I've seem a large frame S&W that had the hammer notches beaten out of shape through too much fast cycling. All guns can break, Rohm just has a much worse reputation for it.