Revolverman,
Thanks for the rapid response and details.
Okay.
4,000 rounds of 158grain .38 Specials is nothing. Your revolver should handle that indefinitely.
1. 0.008" cylinder gap is pushing edge of "serviceable, but it needs fixin".
2. Is there is noticeable radial play, i.e. cylinder rotational play?. Excessive play there would mean your gun is out of time. Look at cylinder bolt stop (bottom of frame) and see if it slops around in it's cutout. Gently holding cylinder against rotation, slowly cock the gun. Does bolt snap into cylinder cutout before full cock is reached? Good timing if it does. Cylinder ratchet or hand or both are worn if it doesn't.
3. Is the barrel indexed correctly (front sight lines up vertically, cylinder ejector rod locks up in lug bolt, crane snug against the frame? If not, crane could be bent (common from snapping gun closed Hollywood style), barrel not fit properly or undertightened.
4. does cylinder spin freely on crane, and when locked in frame? If not, could be bent cylinder ejector rod.
5. bore-to-chamber alignment. If you have access to a range rod (precision ground drill rod with slip-fit in barrel bore. determine barrel bore-to-chamber alignment. Lacking that, try cocking the hammer and peering thru the firing pin hole/chamber/bore at a strong light. Look for cylinder misalignment in one or more chambers. Common for one to e slightly off. If all or most are misaligned, something DEFINITELY wrong.
6. S&W had some big recalls in the early to mid-1980's for barrels that got out with bad forcing cones. S&W Service Center recall notices went out to big law enforcement agencies. Lead and jacket spitting, etc. Problem fixed by re-cutting forcing cone. This is easy to do from muzzle with a pull-type cone reamer. 10 minutes including cleaning out chips. Dunno what degree angle it was.
7. If your gun passes all these checkpoints, it needs gunshop inspection by a certified revolver smith.
HTH
John