Yesterday I ordered another test nipple from October Country Muzzeloading here in Idaho...
http://www.octobercountry.com/
This hardened Stainless Steel nipple was suggested by another forum member 54bore on another site.
Today the nipple arrived - I got to say I open the package not expecting it to work - BUT!!! It is an excellent fit!
The cap is tight and will be water proof
The nipple is longer than a stock Knight measuring .678 - which is long as compared to a stock Knight nipple
Flash Hole - the hole is small .028/29 and I will need to drill it out to .031
Again the down side is to get the nipple off the post you will need to shoot it off or peel it off with the edge of a knife....
The next step is to install it in DISC and see if the hammer/firing pin can hit the cap hard enough to drive it to ignition...
Still have some new Knight Red Hots coming for evaluation...
I just feel good finding one that works the way I prefer - thanks 52!