I have an Old Army, and would be glad to share my meager experiences.
-I have never used filler. I shoot 30-35 grains of powder, with a round ball. There was a thread on the use of fillers here just a month or two ago...
-I used #11 Remington brand caps. Long story short- I got some (unknown brand/size) caps from the previous owner, and they pretty much needed 2+ hammerstrikes to fire. I switched to Remington #11s, and have a virtually 100% fire rate now.
-I use a "snail style" capper. Works well for me. The caps are usually split and just fall off after firing. Sometimes you have to pick one or two off with a fingernail. A couple of times I've had spent caps hang up and bind up the revolver, but like I said- only a couple of times.
-I grease over the chamber mouths. I can shoot dozens of rounds without binding up. I usually wipe things down as they're getting messy, and haven't had buildup problems. I think most buildup problems would be more related to powder fouling(?).
-I've used Pyrodex "P" exclusively, only because it's widely available in my area.
Happy shooting. To lift a quote from a thread I saw here or elsewhere recently, "If you aren't making a mess, you're not doing it right!"
