SORRY. THIS IS DOUBLE POST. I DON'T KNOW HOW TO UNDO.
Jack, when was the last time you replaced the nipple? Depending upon how well set-up is your lock, the relationship between impact face of hammer and cap may be incorrect.
Although hammer's impact face and naked nipple are not supposed to touch when hammer is down, this ain't always the case. If the hammer beats the nipple face, you may wind up with a short nipple, or a deformed one.
If the nipple has shortened, contact between hammer's impact face and cap may be poor.
You can check this relationship yourself, or take your rifle to a muzzleloading gunsmith. Regardless what happens, use a new, properly installed nipple for zeroing and hunting.