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I sharpen my flints on a whetstone. I use crocous cloth to polish up the frizzen face and get better sparks and longer flint life with a smooth frizzen. I dry all oil off the frizzen with a cloth before I load up. I wipe the residue off the flint every few shots. Bevel up or down is not a concern so long at the flint hits the frizzen at least halfway up from the priming pan.
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Thanks for the input, Adam....I have already done most of this. As for where the flint strikes the frizzen, it is hitting up on the higher end of the frizzen (I will try and post a pic later).
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I had the same problem with a Thompson .45 Hawken rifle. I contacted Thompson and explained my problem and they sent me a new lock and frizzen, no charge. Come to find out almost all of those early Thompsons had that problem. I still Squirrel hunt with it. You might see if you can contact someone with the same rifle and see if they are having similar problems.
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I posted this question on another muzzleloading website, and someome said that the Lott locks used by Pedersoli are crap, and to get a new lock from TOTW. Any thoughts on that?
Thanks again guys for the responses...........