Musket Caps Range Test

I have been making musket caps from soda can aluminum as well as reloading commercial hat type musket caps. The reloads are a total success but those of soda can aluminum are too weak. They blow out the back and side without sending enough spark down the ignition channel. After I returned home, I tried one with double thickness of aluminum and it also blew out the back and side. I think I need heavier gauge aluminum.
While out there, I put a round through my Investarms Hawken, a few rounds through a couple Uberti 1847 Walkers and shot my Interarms Virginian Dragoon .45 Long Colt loaded with black powder and .454 diameter balls.