Just for the record, in the show mentioned above, the mock weapons were used by the massive chorus. They did not produce the flash and
smoke at the frizzen as a real flintlock would do. However they were far from the audience and after the first salvo of rounds, there was so much black powder
smoke from the muzzles, no one could tell. There were 6 real flintlocks carried by the principals for their
downstage action. Like real life, misfires were so common with flintlocks that there were two weapons for each actor in each scene. Misfires could be caused by simple humidity in the air if the pan is charged too far in
advance, or the priming charge can
spill out if the weapon is handled too carelessly or too roughly. And NO, the actors did not load the real flintlocks. I did. The hard part was figguring out a reliable way to prime the pans in
advance and not have them
spill out by the time the action occurred. The solution was to make a very small "tea-bag" with flash paper and primeing powder, then poke a hole in the bag and place it over the nipple then a couple of very small strips of ordinary scotch tape. the tape burned away but left a little goo that had to be cleaned off every day. The actors had no powder in their cartridges and they palmed the dummy cartridge and only mimed stuffing the wrapping with a ball in it down the
barrel. They did use the ram rod down the
barrel, but I had shortened them so they did not actually reach the load when the actor did it.
Bit of history. Revolutionary soldiers DID use cartridges whenever possible. Picture a very fat "joint" with the paper twisted at each end. the contents were of course, black powder and a lead ball. To load, the soldier would bite the ball and tear the cartridge apart and then pour the charge in. He would then place the wrapping over the end of the bore, stuff the ball in with the paper serving as the patch and ram the load home. Last he would hold the weapon
level, open the pan and prime, close the frizzen, cock, aim and fire. The cartridges were the preferred method of loading as it was much quicker, it could be prepped in
advance, the soldier didn't have to think about measuring the charge, the "paper" was soaked in a nitrite solution and was similar to flash paper.