Did you load the gun with powder and patched ball to test it?
Simply loading powder without ramming a ball on top of it to seal it may not create a noticeable explosion of a powder like Pyrodex. It needs to be compacted and sealed with the ball on top of it or a wad of compressed newspaper for it to be able to ignite with an explosive effect that you would be able to notice.
buggley said:
i have cleaned the nipple and even took a small welders file to it it see if there was a stopage anywhere betweel the powder and cap and it all checks out.
Or you may not have not checked out flash channel thoroughly enough.
Does air or liquid pass through the flash channel?
If you blow through the nipple hole or push the ramrod with a tight lubed patch down the bore, does air escape out through the flash channel?
You should surely hear the air hissing out of the nipple.
Simply igniting a percussion cap should result in air coming out of the muzzle which can be tested for by doing it in front of paper or blades of grass and watching for movement.
There could be a blockage of some sort that you didn't know about.
Sometimes the blockage needs to be blown out by placing some powder under the nipple, or by using a wire and pushing it out in guns that have a straight flash channel.
You said that it's clear, but are you sure?
Another possibility is that the powder is bad, the granulation of the powder is too large, or that the powder chamber at the bottom of the barrel won't let the powder get close enough to the flash hole for for the cap flame to ignite it.
But that's not quite the same as a flash channel blockage, or not sealing the powder with something to seal it off, such as with a compressed wad of newspaper.
Did you actually load the gun at the range to test it?
How did you test it with powder?
If the powder was loose and didn't seem like it went off normally, then maybe it wasn't sealed with the ball or a wad to develop enough pressure to create an explosive effect, and the powder just fizzed. That's what it does when the powder is not properly sealed after it's loaded into the barrel.