Thanks for all the comments.
I checked the spacing between the cylinder and the bbl throat and a .003 feeler fits with slight play. The next size I had was a .006 and it would not go, so I figure it is about .004 -.005.
The 2 powders I used are probably 10 years old or so, been shooting Unigue in my 45 and 9mm and 20 ga. so have not needed them.
I am going back to the range this morning and have some factory Blazer 158gr jacketed to try double action.
If everything goes ok I plan on picking up some fresh powder this weekend. All in all I am hoping I do not have to send it back again!