OP HERE........Thanks for all the comments. I did realize that the same numbers from different manufactures will not be the same. I did not know that a Pietta gun with original nipples will not be consistent with all other Pietta guns that still have original nipples. So now I know not to count on consistency from either the caps or the nipples.
Someone is sending me a few different cap sizes to try, and some .451 & .457 balls to try. I had already ordered a box of .454 balls. Hope those fit, but I will see if the .451 or .457 are better for the next order.
No one local that I know shoots BP revolvers. The LGS only carries FF for a few folks around that have some in-line hunting guns (rifles). They also have a few rifle sabots and bullets but no round balls in revolver calibers. They do not have any other customers asking for supplies for BP revolvers. They do not carry any caps at all. His supplier will not sell him any quantities of caps smaller than a case lot and he would never sell an entire case in a couple of years. He said what is strange is that his supplier will deliver primer orders as small as 1000 primers (one brick). This LGS has a good supply of reloading goods as long as it is smokeless. I buy all my smokeless powder and primers there.
I will be buying all my FFF and caps in San Antonio at the Powder Horn, which is 80 miles east of here. I've got the Dixie Gun Works catalog and have read up on the vast amount of info that it offers in the articles. I have also been reading everything on this forum about BP. It has helped a lot. I've been reloading smokeless for years so the concepts are not completely new to me.
Looking forward to picking your expert brains in the future.
Twobit