Sixgun - Believe me, I've been all thru that kind of stuff. None of the problems you had were what I have going on with the 35Rem. I get primer strikes every time. It doesn't appear to be a hammer-block problem. All other barrels shoot just fine on the same frame (incl. rimmed and rimless rounds). If I keep trying, every round will eventually go off. Some take up to 3 or 4 tries to get them to finally go. Great practice to make sure you don't have the flinches :roll: !!!!
All rounds fall flush with the rear of the barrel and there is only 0.004" gap between the frame and barrel ... shouldn't be enough to have misfire problems. Even once fired brass (other than Federal) doesn't go off every time. I've thought of getting a .375" tapered expander and making a false shoulder to take up the 0.004" gap, but haven't gotten there yet.
Other than that I'm at a loss .... like I said, it's either get rid of it or get it rechambered. It is kind of a unique barrel in that it has no crown. The end of the barrel is perfectly flat with just a slight chamfer at the ends of the rifling. It is marked "Super 14" and measures 14", so it hasn't been cut down which was my first thought. It shoots fine (some 180gr reloads, when they go off, have been WAY less than an inch ... 3 holes in a cute little cloverleaf).
Just venting my frustrations! ... Crayfish