Ill fitting percussion caps are dangerous. If the cap is oversized, they can either fall off allowing burning powder from an adjacent chamber being fired to get down and set off the chamber with no cap covering it resulting in a chain fire.
The best advice that I can give, is get some Treso nipples to fit it- they are made of bronze and are designed to be used with Remington #10 percussion caps which fit them perfectly. The Treso nipples also have some very, very small flash holes which 99% of the time keep the caps from splitting and coming off when they are fired. The disadvantage is you will have to gently use your fingernail to pull them off the nipple after they are fired- but this keeps them from falling into the action and makes it much, much more reliable.
I've had no misfires or cap jams at all since switching to Treso nipples. They can be bought at Track of the Wolf, the Possibles Shop or other various retailers. They run about five dollars each, but a small price to pay for reliable shooting.
The one other item I will suggest, it use real black powder- it doesn't matter the brand (Goex, Swiss, KIK, Diamondback, or some old Elephant), but it will ignite much easier and shoot more consistently that most any substitute. A good place to start for a decent load is half the caliber- .44 caliber, so 20 to 25 grains- which makes a great plinking load which doesn't use too much powder.
I can understand why having so many problems may have turned you off from shooting such a nice revolver so much- I used to struggle a bit when shooting percussion, but it's very enjoyable once you have reliable shooting pieces.
The blackpowder bug has bitten me and I'm infected.
