Muzzleloader blank black powder charge pressure: Are double charges dangerous?

Herman Karl

Many reenacting groups have adapted 120-125 grains of FFG black powder as the
standard and maximum safe blank load for .69 to .75 caliber muskets. The National Park
Service in Manual for the safe use of reproduction flintlocks in historic weapons
demonstrations, specifies (p. 45) that 125 grains FFG is the maximum blank charge for
.69 and .75 caliber muskets, but does not discuss how that amount was determined. To
make more noise at demonstrations some groups “double charge.” Is a charge of 240-250
grains FFG safe in a reproduction flintlock musket? A recent conversation on the Rev
War reenactors Face Book page highlighted the dearth of hard data available to inform a
controversial discussion about the maximum safe charge for a muzzleloader blank black
powder load (see,
https://www.facebook.com/groups/217402738422205/search/?query=blank%20loads).
The conversation was started to decry what the discussants described as the irresponsible
and dangerous practice of using a 210-grain blank black powder load (clarified as the
discussion evolved to be 240 grains of, I presume, FFG) by a reenacting group. Although
never specifically stated I infer the concern was that a large charge might burst the gun
barrel owing to excessive pressure. Discussants offered opinions none, however, based on
actual pressure data. The absence of data did not deter the group from arbitrarily reaching
a consensus that 120 grains is the maximum safe blank black powder charge for a .69 to
.75-caliber musket. I have searched diligently for pressure data for blank black powder
loads, but have not been able to find any. So, I decided to collect some.
With a Recreational Software Pressure Trace II system
(https://www.shootingsoftware.com) I acquired pressure data that include two live tests
with ball, reported below, using my reproduction 1730 Long Land Service pattern
musket. The caliber is .77 and barrel length 46”. Data were collected November 11, 2018.
The temperature was 32 degrees. Most reenactors use FFG and data below were obtained
using Goex FFG; the charge was measured volumetrically.

1. 120 gr., .735 600 gr. ball, no patch; chamber pressure 2993 psi, muzzle velocity
(15 feet) 977 fps
2. 120 gr., .735 600 gr. ball, no patch; chamber pressure 2812 psi, muzzle velocity
(15 feet) 706 fps
3. 120 gr. blank, chamber pressure 925 psi
4. 120 gr. blank, chamber pressure 920 psi
5. 240 gr. blank, chamber pressure 1533 psi
6. 240 gr. blank, chamber pressure 1378 psi
7. 240 gr. blank, chamber pressure 1642 psi
8. 360 gr. blank, chamber pressure 2831 psi.

These are the only reported pressure data for blank black powder charges of which I
am aware. Factors that affect chamber pressure include bore size and barrel length, and
for black powder, granulation size. Fadala in the 5th edition of “The complete black
powder handbook” states, p. 211:

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 Bore size determines pressure, as we know from pressure gun readings.
For example, a 36-caliber squirrel rifle firing a 65-grain round ball in
front of 50-grains volume GOEX FFG black powder shows a psi rating of
11,200, while the same GOEX FFG charge in a 50-caliber rifle pushing a
177-grain round ball generated only 2,900 psi. Granulations also make a
difference in pressure. Example: 50-caliber rifle, 177-grain round ball,
70-grains volume FFG Elephant Black Powder, 6,100 psi, 70-grains
FFFG Elephant Black Powder, 8,300 psi.

The purpose of this note is to provide a limited set of pressure data for blank
powder loads specifically in response to the discussion cited on the Rev War reenactors
website. The data herein indicate that pressure generated by blank charges is very low.
Given these results I see no point to undertake a comprehensive experiment to test
various charges of black powder in guns of various calibers.
For further comparison and a discussion of muzzleloader pressure see:
https://www.chuckhawks.com/muzzleloading_pressure.htm from which the following is
cited.

From the Lyman Black Powder Handbook, 2nd Edition, p.p. 171-172:
13,500 PSI, 15,400 PSI, 15,100 PSI, 16,800 PSI, 22,600 PSI, and 23,400
PSI. That is a spread from 13,500 PSI to 23,400 PSI, with one load
developing over 73% more pressure than the other. So far, so what? It just
looks like a bunch of numbers, and so it is.

However, all these pressures came from the SAME .50 caliber 22 inch 1-24
rate of twist test barrel. All these pressures were developed using the SAME
240 grain Hornady saboted bullet. All these pressures were developed using
the SAME 100 grains volumetric measured charge of black powder or a
black powder substitute. ... Higher velocity does not necessarily mean more
pressure, and recoil does not automatically indicate higher or lower
pressure. Not only that, heavier projectile weight does not automatically
mean higher pressure, either. On p. 173 of the same Lyman manual, a 300
grain Hornady bullet/sabot pushed by 100 grains of Elephant FFg produces
only 14,300 PSI. That same Elephant FFg produces more pressure with the
lighter 240 grain Hornady XTP/sabot. Same way with the two pellet load:
the tested pressure drops with the use of a 300 grain Hornady sabot
compared to a 240 grain Hornady sabot.

For a comprehensive study of smokeless and black powder pressures see: Bell,
Sherman, 2002, Finding out for myself, part VI, smokeless vs. black: Double Gun Journal,
summer 2002, v. 13, n. 2, p. 19-32.
Of course, a “safe” load, among other factors, depends upon the quality and
condition of the gun barrel and fit of the breech plug. In that regard the quality of Indian-
made replicas is another topic that fills the reenacting websites and forums. A quick
search revealed little actual data and a great deal of misinformation and opinions, which
are repeated across the forums until they become the stuff of myth. It is the responsibility

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of the shooter to make sure that the firearm is in good condition and safe to use. Indeed,
the shooter is the most important determinant of safety.
These data are offered without recommendation as to appropriate blank black
powder charges. They are intended to put facts on the table to inform knowledgeable
discussion and discourage unfounded opinion, defined in the dictionary on my desktop as,
“a view or judgment formed about something, not necessarily based on fact or
knowledge.”