That's what really has me confused. I clean with soap and water just as you described, the last time I shot it and had the misfires I ran dry patches thru it to reduce the bore butter which I use as a preservative between shooting sessions, then I shot 30 grs to foul the barrel, cleaned with 1 patch of windex and 3 dry patches, took 2 shots, cleaned with the windex in between, and had the misfire. I tried a nipple pick to clear the channel without luck and pulled the bullet and removed the load. The powder was packed pretty tight so I used the bullet puller to break it up, cleaned again with the windex, fired 1 more shot, cleaned with windex, then had another misfire. With some work with the nipple pick I was able to shoot that load after 3 percusion caps. The residue I removed between shots had the appearance of pencil lead and may have even been some lead from the bullet, they were a tight fit. The first 6" was pretty tuff but than they went right down the barrel, I don't think that was out of ordinary though. The bullets are pre lubed Hornady Great Plains, 295gr. The nipple only has maybe 30 caps thru it.