Well shoot. I guess I don't know what I am talking about. :roll:
I should leave it at that, but I did a little more tinkering with mine and found the problem. I originally thought the problem was the location of the hole for the pawl, but if that was the case it would bind at lockup. The problem was the top of the hammer was a bit long and didn't let the pawl fully retract when at rest due to the fact that the hammer didn't "rest" at the same depth as the original hammer. That is where the 12 clicks per rotation came from. I removed a bit of the face of the hammer and the extra clicks went away. I now only click from the plunger and it locates correctly as it is designed to do. I also took a bit more off the second step to do away with the transfer bar pinch. Everything now works properly. If Mr. March has clicks when rotating the cylinder with the loading gate open after removing the plunger assembly, then he has the same issue I had.
Again, the SBH hammer will function as is in a New Vaquero, but you will have transfer bar pinch due to the difference in transfer bars between Supers and NV's. This can be fixed by filing the second step. The freespin pawl will not fully retract at rest due to differences in the depth of the face of the hammer. Again, can be fixed with filing. File the upper face of the hammer until the pawl retracts far enough to clear the ratchet. Then you will only have six clicks and it will index properly at the click to eject/load. Once you have done that, check for transfer bar pinch. After firing, hold the trigger back. Watch the hammer. Does it move farther foreward when the trigger resets? If it does, you have pinch and need to remove metal from the second step in the hammer (the part that actually hits the transfer bar to fire). Once those two problems are addressed, everything else should be fine. The only other possible problem could be the weight of the hammer coupled with a weak mainspring. I have not had an issue with misfires tho...
But then again, "I don't know what I am doing" according to Mr. March.