I tried CCI as well as both Magnum and Standard Winchester caps, three different caps in all. The CCI caps are over 10 years old.
The hammer hasn't been worked for over 10 years so maybe a little use will loosen and strengthen the strike, I did spray a little gun oil in the lock thinking that would help.
As far as the nipple being worn I used the new nipple that came with the new barrel, I also have a new CVA nipple that I could try. Another thought is the hammer strikes the nipple but not dead center, I didn't see a way to adjust this at all so I figured it was normal. Does the hammer need to strike dead center?
As you can see I don't know much about muzzleloaders but am really looking forward to shooting this one soon.