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Baffles may be of larger diameter than the end cap. For example, SilencerCo Omega has a 7.62 end cap and also a 5.56 to help cut down a few decibels on the smaller diameter round. Just need to make sure you put the larger cap back on if using it on different calibersI cant tell if its lead or whatever material the end cap is made of. Makes absolutely no sense why it would strike the cap and not touch any of the baffles unless the cap is drilled just slightly off centered.
Yes no washers, can directly to the muzzleYou are screwing the can on without any spacer, lock washer, or crush washer, right?