a while back I was wondering about how much of a seal the balls would make. I loaded a few without powder, the removed the nipples and drove them out. I was surprised that while only a small ring of lead was shaved off, there was actually a rather large flat surface where the ball contacted the cylinder. I had not thought about this before, but the soft lead would deform until it could not be compressed any more, then the thin ring would be shaved off. after seeing this, I an convinced that chain fire would be very unlikely from sparks caused by firing. Plus, any sparks would be propelled away from the cylinder. I think that a chain fire would be more likely from the caps being set off from the recoil. I know I have a very hard time finding caps that fit well for my repro revolver, and it frequently will jam if I can't find a brand that fits well. during the war, I'm sure it was hard enough just to get caps for the revolvers, any you would have to use whatever you had regardless of how well they fit. I'll admit I have always grease the chambers, but now I think that it is really more of an issue of providing lubrication for the ball.