The Miss Cap
After hours of research and testing, I'm confident enough to say that the miss cap

for Warriors(and most likely Paladins and Death Knights) is
16.
I'm going to briefly explain the final few rounds of testing I did to arrive at this conclusion, every round has a screenshot that shows the gear I used, mobs, mob level, my avoidance stats, combat table calculation using best guess miss cap, and Recount stats.
Test method design
Goal: Obtain the chance to be missed% after DR
How are we going to do that? Just getting hit millions of times will not give you exact numbers.
The only reliable way is to test for block cap, when you are block capped you can not be hit, the only outcomes of a mob swing are missed, dodge, parry, and block.
When you are
exactly block capped, because we know the exact dodge, parry chance after DR and block chance, we can calculate the true missed chance after DR.
The key word is
exactly, meaning to gearup as close to block cap as possible but not over it.
Since I'm also the author of TankPoints, I first modify the misscap TankPoints code to my current best guess, choose gear according to this guess and start testing if the guess was good or not, loop again with a better guess.
I chose level 7 mobs for my tests, I'm a level 60 warrior, so that gives me 10.6% Block, 10.6% Dodge, 10.6% Parry, and 10.6% Missed, for a total of +42.4% avoidance from level.
Test 0
Goal: Does avoidance from level difference does not suffer from DR?
How: Choose the right amount of gear so I would be under the block cap if avoidance from level difference suffers from DR, but over the block cap if it didn't, and see if I would get hit or not.
Results: I did not get a normal hit after 500 or so hits
Conclusion: Avoidance from level difference does not suffer from DR.
Test 1
Image:
http://img253.imageshack.us/img253/7...9222135yj2.jpg
How: Gear up to 100.08%. As shown in Combat Table in the image, Block is capped by 0.08% so we are at 100.8%. Miss in the Combat Table is calculated assuming a miss cap of 20%, if this assumption is correct, I will not get hit.
Results: I got hit 3 times in 2552 swings, about 0.11%
Conclusion: The miss cap is lower then 20%.
Test 2
Image:
http://img98.imageshack.us/img98/877...9232535ht4.jpg
How: Add about 0.09% more avoidance to my gear, and test again. Assuming a miss cap of 17% this time, I should only have a hit chance of 0.01%.
Results: I got hit 4 times in 5044 swings, about 0.07%
Conclusion: The miss cap is lower then 17%.
Test 3
Image:
http://img179.imageshack.us/img179/3...9004707xb3.jpg
How: Assuming a miss cap of 16% this time, I managed to gear myself to 99.99876% avoidance, meaning I'll only get hit once every 80000 swings on average if the 16% miss cap assumption is true.
Results: I got hit 0 times in 8289 swings, I had to stop here because my shield was at 2% durability.
Conclusion: I'm either already block capped, or very very close. Need to do more tests.
Test 4
Image:
http://img179.imageshack.us/img179/2...9010110bj4.jpg
How: Still assuming a miss cap of 16%, I managed to lower my avoidance by 0.025% to 99.973%, meaning I'll get hit once every 3700 swings on average.
Results: I got 1 hit in 1639 swings so I stopped
Conclusion: I was very close to the block cap in Test 3, because I got hit by lowering my avoidance my a tiny 0.025%.
Test 5
Image:
http://img407.imageshack.us/img407/2...9021149qk1.jpg
How: Do more tests with the same gear as Test 3, with a theoretical avoidance of 99.99876%.
Results: I got hit 0 times in 9656 swings, shield durability 1%.
Conclusion: I think 16% miss cap is preety good
Test 6
Image:
http://img407.imageshack.us/img407/2...9025517hz4.jpg
How: I managed to lower my avoidance by a wee bit of 0.005% to 99.99311%, meaning I'll going get hit once every 14513 swings on average.
Results: I got 1 hit in 6388 swings so I stopped
Conclusion: By lowering my avoidance by only 0.005% I got a hit, meaning Test 3 and 5 are very close to block cap
Test 7
Image:
http://img120.imageshack.us/img120/3...9035848so7.jpg
How: Do more tests with the same gear as Test 3, with a theoretical avoidance of 99.99876%.
Results: I got hit 0 times in 8381 swings
Conclusion: I'm going to say 16% miss cap works preety well.
The lastest alpha version of
RatingBuster and
TankPoints are now updated with a 16% hit cap for calculations.
At 540 Defense, your chance to be missed is 9.288%.