Howdy again Charlie,
I wonder if you saw a nice ring of lead come from those balls when you rammed them. I always do with speer 457 balls. If not, then you may very well have a cylinder or cylinders that aren't right.
35gr load of 777 must be stout. I tried a 30gr load and it about spun me around. I shoot cowboy action where big muzzle jump and a lot of recoil won;t do much for your scores. I do know cowboy shooters that shoot 777 as low as 15gr in there ROAs, but I don't think it is enough smoke for me, so I have been shooting CleanShot/American Pioneer. How can they load 15gr you are now wondering and have the ball compress onto the powder? Well, extended rams is the answer. You could however stick a loose 38 lead bullet onto the ball after ramming to ram it once again and seat the ball. Now I run extended rams on my ROAs myself, but that is because I do not use wads. I just add 30gr of CS and ball and ram. This is great and accuracy is there for me at 15 yards. That is about as far as I see pistol targets out and a lot are more like 10 yards. I had to file my front sights. This is cowboy stuff and it is a speed contest. In your case, if you can handle 35gr of 777, I would try that for a while. Do not mess with sights unless you decide on a keeping a specific load and powder in your shooters. You cannot very easily put metal back on. Ruger should stand by their product, but I have never heard of bad cylinders myself. Most complain about windage on the front sight and I have one I found to shoot right on me. I corrected it when I opened up my rear sight notches, another cowboy thing for faster aquisition times. No I do not have anything I shoot that is box stock and not many cowboy shooters do, but mine are not race guns either. I do have a pair of 51 Navys that I will be souping up this winter, by cutting the barrels to 5 1/2" and welding the slots for the hammers and all that kind of stuff. I hope you can get yours shooting right, if not send it back to Ruger and hopefully they will get you fixed up. :grin: