I had a similar problem with an encore. I ended up sending it to T/C 5 times in total. 3 for inaccurate muzzle loader barrels. each time they replaced the barrel and sent it back. Upon giving up on the MLs I bought a 25-06 barrel, and continued to have problems. It turned out to be a headspacing problem due to a large barrel/frame gap. The gap was so large it would not consistently ignite primers. I sent it to T/C. They fired 10 factor loads through it and sent it back as it was. I called them and discussed the problem. They said the gap was within specs and since it fired 10 times in a row it did not warrant repair. They did suggest that I size my brass so that the shoulder was fireformed forward to compensate for the gap. Next we discussed that this 25-06 barrel was chambered so that 120 grain bullets must be seated significantly shorter that specs dictate. They said I was wrong. I suggested I video me blowing up the rifle with a 120 grain bullet factory load. They suggested I send it back again. They replaced the barrel, all of the internal parts (undoing my trigger job), and the stock. This barrel has a much smaller barrel/frame gap and shoots my handloads at moa for 5 shots at 100 yards, it may do better if I worked at it a little more. I will probably not mess trying to put any more barrels on that frame because I think they probably tried different barrels until they found one that fit, so there would likely still be a gap issue. I also feel like since the rifle had been to the factory multiple time an they had not had an issue with my trigger job, undoing it this time was a little F-U for bothering them with my persistence. I think I am done with the new T/C, but I will continue to enjoy the older contenders.
