both problems some what solved.

I went I got some 3/16" weather striping. placed it on the barrel on one side opposite the nipple, than 2 in one both sides of the barrel lug. which gave me enough space to push the nipple enough to give me enough clearance for a nipple with a cap to be hit with the hammer with out hitting the sides.

did the test with a rem #11. the cap was really really loose on the nipple. almost think the nipple is an #10 nipple. where the F did I get an #10 from? I don't own any BP 6 shooters.