Back in 1989 I had seen EMF cap & ball revolver adds in the Shotgun News, later they with cased revolvers, I orderd 2 one a 1860 .44 steel framed revolver, and a Colt walker (after 3 back orders on the walker the refunded my money) I was living/working in Barrow AK, No precussion caps to be found in that town!!, I had co-workers on the prowel on ther trips outta town but either they forgot, were too busey or came up empty, I finnally got a chance to get to Anchorage, picked up some Pyrodex P from the trip to Anchorage, hit 4 different shops they were either out of caps in the size I needed or dident stock them, dejected I returned to Barrow stewing that I had a cap & ball revolver with Powder and shot and nothing to set them off with! after a couple months I had a powerfull urge to shoot it and started looking round for alternave's, I picked up some plastic cap gun cap's to the grosery store they fit the nipples and would even pop once in awhile but not ignite the powder!
I was paruseing the Dixie Gun Works Catalog and saw the Tap-O-Cat tool to make your own percussion caps
I dident want to spend that kind of money for the Dixie product, the idea stay'd in the back my mind.
Acting on what that DGW add said I picked up a paper punch (swiped from the secratary's desk) and proceded to punch disc's from a alum coke can, I made a small die block of oak pallet wood, I'd place a disc over the slight depression and dimple the disc then the next progressively deeper depression till I had a crudely formed aluminum cup, I picked up 3 boxes of them paper cap's on rolls and very carefully used my cuticle scissors and cut round the cap (its painfull when they pop on your in your grasp!) I'd put little dab of paper glue in the cup and stuck the cap dot in the cup (pretty work intensive) desperation leads to getting inventive, they did work and were a pain as they dident stay put as well as factory caps but they did fire the revolver!! just as I started useing them a week and half later one my co-workers brought me a single tin of Remington #10 caps! they fit like a saddle on a sow but worked better than my home made ones so my experiment of makeing caps stopped, I think that if I had stay'd at it they would have turned out better ones.