Sorry for the delay in replies - I've been away.
The rifle is a recent (2005) full-up custom by Jack Haugh in his wildcat 416 Haugh. It's a first-class rifle in every respect. I am very proud of the rifle and take good care of it (clean it regularly, use a bore guide, etc).
I agree that the sear didn't reset to catch the cocking piece. I am going to have it apart this week and will give the trigger a good visual for residue, reset spring issues, etc. The fact that it is a pretty new 1-owner rifle and well cared for make me doubt that I will find much build-up, but I won't rule it out.
I want to stick with an all-steel trigger because I just don't like aluminum, unless it is a 12 or 16oz container from St. Louis. I've been looking at the Recknagle from NECG and a couple others that escape me right now. I'd really like to keep the Blackburn in the gun. However, this is the second time I've had trouble with it and the thought of 5000+/- ft-lbs of muzzle energy through an un-mounted rifle is nothing I want to experience.
I'll try to get some pictures when I have the metal out of the stock.
Thanks for all of the well thought-out and helpful responses!
Bryndon